D 427 Diezel Engine

SB4034E00
Jul. 2000
Engine
For Skid Steer Loaders
D427 Diesel Engine
1550XL(DSL702)
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
Engine
2.1. General Information
Index
Engine
Cooling System
Specifications ............................................................5
Troubleshooting Guide ..............................................6
Adjustment of Cylinder Head Valve Clearance/Idling....8
Adjustment of Valve Clearance .................................8
Idling
Inspection..............................................................9
Adjustment ............................................................9
Injection Timing
Inspection..............................................................9
Adjustment ..........................................................10
Checking of Compression Pressure........................10
Disassembly and Assembly.....................................11
Inspection and Adjustment
Cylinder Head .....................................................21
Valve....................................................................24
Valve Spring ........................................................24
Push Rod ............................................................25
Tappet .................................................................26
Rocker Arm .........................................................26
Piston and Piston Ring........................................27
Connectng Rod ...................................................29
Connectng Rod Bearing......................................30
Crankshaft...........................................................31
Main Bearing .......................................................32
Cylinder Block .....................................................33
Cylinder liner .......................................................33
Camshaft.............................................................34
Gears ..................................................................35
Oil Seal................................................................36
Specifications ..........................................................42
Troubleshooting Guide ............................................42
Thermostat
Removal ..............................................................43
Inspection............................................................43
Installation ...........................................................43
Water Pump
On-Vehicle Inspection .........................................44
Removal and Inspection .....................................44
Disassembly and Assembly ................................44
Inspection............................................................45
V-Belt
Inspection............................................................45
Fuel System
Outline .....................................................................46
Structural View ....................................................46
Specifications ......................................................47
Fuel Filter
Removal and Installation.....................................49
Air Bleeding.........................................................49
Water-Drain .........................................................50
Replacement .......................................................50
Injection pump
Structural View ....................................................51
On-Vehicle Inspection and Adjustment ...............52
Removal ..............................................................53
Installation ...........................................................54
Air-Bleeding.........................................................54
Injection Nozzle
Structural View ....................................................55
Removal ..............................................................55
Inspection and Adjustment..................................55
Assembly.............................................................57
Installation ...........................................................57
Lubrication System
Outline
Structural View ....................................................37
Specifications ......................................................38
Inspection
Checking Oil Pressure ........................................39
Oil Pump
Disassembly ........................................................39
Inspection............................................................40
Assembly.............................................................41
Oil Pan
Removal ..............................................................41
Installation ...........................................................41
Inspection............................................................41
Diesel Engine D427
Index
Engine Electrical System

Specifications ..........................................................58
Starter
Removal ..............................................................60
Installation ...........................................................60
Free Running Test...............................................60
Disassembly ........................................................61
Inspection............................................................62
Alternator
Circuit Diagram ...................................................65
Charging system cautions...................................65
Checking No-Load Adjustment Voltage ..............66
Checking Output .................................................66
Removal ..............................................................66
Installation ...........................................................67
Disassembly and Assembly ................................67
Inspection............................................................69
Glow Plugs
Checking Open Circuit of Glow plugs .................70
Technical Data ..............................................72
Diesel Engine D427
Index
Engine
Specifications
Specifications
Engine model
D427
Type
Diesel, four-cycle
Number and arrangement of cylinders
Four cylinders, in-line
Displacement
cc
Type of combustion chamber
Swirl floor type
Valve system
Over head valve(O.H.V)
Bore and stroke
mm X mm(in X in)
Compression ratio
Valve timing
Exhaust valve
Open
BTDC 14
Closed
ABDC 44
Open
BBDC 48
Closed
ATDC 10
Injection Timing
ATDC 2
mm(in)
Intake
0.30(0.012)
Exhaust
0.30(0.012)
Idling speed
rpm
Firing order
Diesel Engine D427
92.0 X 101.6(3.62 X 4.00)

21.5 : 1
Intake valve
Valve clearance
2701
1100 L 25
1-3-4-2
Engine
Troubleshooting Guide
Problem
Insufficient power
Possible Cause
Insufficient compression
improper valve clearance
Compression leakage from valve seat
Seized valve stem
Weak or broken valve spring
Cracked or distorted cylinder head
Sticking, damaged, or worn piston ring
Cracked or worm piston
Malfunction of fuel svstem
Excessive oil
consumption
Remedy
Adjust
Repair
(grind the valve seat)
Replace
Replace
Replace
Replace
Replace
Refer to Group 4
Oil working up
Worn or sticking piston ring or piston ring groove
Worn piston or cylinder
Oil working down
Bad valve seal
Worn valve stem or guide
Oil leakage
Replace
Replace
Refer to Group 2
Malfunction of engine-related components

Burned valve
Worn piston, piston ring, or cylinder
Burned cylinder head gasket
Malfunction of fuel system
Malfunction of electrical system
Replace
Replace or repair
Replace
Refer to Group 4
Refer to Group 5
Abnormal
combustion
Malfunction of engine related components

improper valve clearance
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber
Adjust
Replace
Replace
Eliminate the carbon
Refer to Group 4
Poor idling
Malfunction of engine-related components

Improper valve clearance
Poor valve to valve seat contact
Failure of cylinder head gasket
Adjust
Repair or replace
Replace
Refer to Group 4
Difficult starting
Diesel Engine D427
Replace
Replace or repair
Engine
Problem
Engine noise
Diesel Engine D427
Possible Cause
Crankshaft or bearing-related parts
Excessive main bearing oil clearance
Main bearing seized or heat-damaged
Excessive crankshaft end play
Excessive connecting rod bearing oil clearance
Connecting rod bearing seized or heat-damaged
Piston-related parts
Worn cylinder
Worn piston or piston pin
Seized piston
Damaged piston ring
Bent connecting rod
Valves or related parts
Excessive valve clearance
Broken valve spring
Excessive clearance between valve stem and guide
Others
Malfunction of water pump bearing
Improper drive-belt tension
Malfunction of alternator bearing
Exhaust gas leakage
Malfunction of timing belt tensioner
Remedy
Replace or repair
Replace
Replace or repair
Replace or repair
Replace
Replace of repair
Replace
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
Adjust
Replace
Repair
Replace
Engine
Adjustment of Cylinder Head

Valve Clearance/Idling
Adjustment of Valve
Clearance
Adjustment of Cylinder Head
Fig 1-3
1. Remove the cylinder head cover.
Fig 1-2
2. With the No. 1 cylinder piston at TDC, check and

adjust piston clearance as follows :
1. Remove the cylinder head cover.

2. Remove the head bolts.
Intake side : No.1, No.2

Exhaust side : No.1, No.3
Valve clearance(under cold engine condition)
Intake & Exhaust : 0.30 mm (0.012in)
3. Tighten head bolts to the specified torque, in the

numbered order shown in the figure. Use the
torque wrench.
3. Set the No.1 cylinder to compression TDC by

turning crankshaft, and then check and adjust
piston clearance as follows :
Tightening torque(under cold engine condition) :

11.0 ~ 11.7 mkg (78.6 ~ 84.6 ftlb)
4. Adjust valve clearance when fixing bolts.
Intake side : No.3, No.4

Exhaust side : No.2, No.4
4. Assemble the cylinder head cover.
Diesel Engine D427
Engine
Idling
Inspection
1. Warm up the engine thoroughly.
2. Run the engine at idle.
Standard ldling speed : 1100 L 25
3. Adjust the idling speed if the speed is not within
the specified range.
Fig 1-8
3. Set measuring instrument to injection pump. Make

sure that the filler end of measuring device is in
contact with plunger head.
Adjustment
Adjust the idling speed by turning the idling adjusting
bolt of the injection pump.
1. Remove the lock nut of the idling adjusting bolt.
2. Turn the idling adjusting bolt until the idling speed
reaches standard valve.
3. Tighten the lock nut.
4. Run the engine for about 2-3 minutes and check if
the idling speed is at standard value.
Fig 1-9
4. With the flywheel ring gear in proximity to BTDC

30 find the point where needle of dial gauge
stands still, even when the flywheel is being turned.
Injection Timing
5. When it is confirmed that the needle of dial guage

is not moving, then set the needle of the dial
gauge to O
Inspection
Fig 1-7
Fig 1-10
1. Remove all injection pipes.

6. Turn the flywheel clockwise until it reaches TDC,
lnjection timing is normal if dial gauge indicates
1.00mm at this point.
Adjust if more than 1.00mm.
2. Remove the head bolt and gasket from the

distributor on the injection pump.
Cam lift for optimal injection timing : 1.00 mm (0.039 in)

Diesel Engine D427
Engine
Adjustment
Checking of Compression
Pressure
Injection timing is too early when cam lift value is

more that 1.00mm, and too late when it is less than
1.00mm.
Fig 1-13
Fig 1-11
1. Warm up the engine thoroughly.

2. Remove the nozzle holders from all cylinders.
1. If injection timing is not right, then turn the injection

pump until the dial gauge indicates 1.00mm.
(1) If cam lift value is less than 1.00mm, turn
injection pump in direction of engine rotation to
its maximum, and then adjust the cam lift value
to 1.00mm, by turning it in counter direction.
(2) If cam lift value is more than 1.00mm, adjust it
by turning injection pump in counter direction to
engine rotation, until value reaches 1.00mm.
3. Install the adapter set and use a pressure gauge

of capacity greater than 30 kg/cm2
4. Remove the fuel cut solenoid wiring.
5. Crank the engine and measure compression
pressure.
2. Install the bolts and gasket after adjusting.

CAUTION : Use new head bolts and gasket.
Compression pressure
kg/cm2 (lbin2)-rpm
Standard
30(426)-200
Limit
27(384)-200
3. Install the injection pipes.

CAUTION : If the pressure does not come up to the
specified pressure, check the engine speed.
At normal engine speed, if compression pressure is
less or more than the standard, and the pressure
differences in each cylinder are more than 3 kg/cm2,
it is necessary to disassemble and readjust the
engine.
Diesel Engine D427
10
Engine
Disassembly and Assembly

Disassemble in the following sequence. Assembly is
the reverse order of disassembly.
1. Remove the Fuel pipes.
2. Remove the Starter motor.
3. Remove the Engine mounting bracket.
4. Remove coupler from the engine.
5. Set the engine on the engine hanger
6. Remove the following parts from the engine :
(1) Alternator
(7) Exhaust manifold
(2) V-belt
(8) Ventilation pipe
(3) Crankshaft pulley
(9) Injection pipe
(4) Flywheel
(10) Oil filter
(5) End plate
(11) Intake manifold
(6) Water hose
(12) Thermostat case
Diesel Engine D427
11
Engine
7. Remove the cylinder head parts in the numbered order shown in the figure.
Fig 1-24
(1) Cylinder head cover. (2) Gasket. (3) Rocker arm. (4) Cylinder head. (5) Gasket. (6) Push rod. (7) Intake valve.
(8) Exhaust valve. (9) Valve guide.
Diesel Engine D427
12
Engine
8. Disassemble the piston and oil pan in the numbered order shown in the figure.
Fig 1-25
(1) Piston ring. (2) Piston. (3) Piston pin. (4) Connecting rod. (5) Connecting rod bearing set. (6) Oil pipe. (7) Set screw.
(8) Oil pump. (9) Oil level gauge. (10) Gasket. (11) Oil pan.
Diesel Engine D427
13
Engine
9. Disassemble the timing gear and the related parts in the numbered order shown in the figure.
Fig 1-26
(1) Timing case cover. (2) Gasket. (3) Oil deflector. (4) Injection pump cover. (5) Gasket. (6) Locking bolt.
(7) Thrust plate. (8) Idle gear. (9) Spindle. (10) Crankshaft gear. (11) Lock nut. (12) Lock plate.
(13) Cam gear. (14) Lock nut. (15) Lock plate. (16) Injection pump gear. (17) Timing case. (18) Oil seal
Diesel Engine D427
14
Engine
10. Disassemble the crankshaft, cylinder block and the parts in the numbered order shown in the figure.
Fig 1-27
(1) Main bearing cap. (2) Bearing set. (3) Crankshaft. (4) Thrust plate. (5) Cam shaft. (6) Tappet. (7) Oil seal cap. (8) Gasket.
(9) Oil seal. (10) Cylinder liner. (11) Cylinder block.
Diesel Engine D427
15
Engine
Fig 1-28
Fig 1-31
11. Disassemble the pulley lock bolts and crankshaft

mounting bolts, preventing flywheel rotation
prevent the flywheel from rotating and remove the
pully lock bolts and crankshaft mounting bolts.
14. Remove the valve guide, pushing it towards

combustion chamber by using the valve guide
installer.
Fig 1-32
Fig 1-29
15. Assemble the valve guide in the following order.

12. Remove crankshaft pulley by using the taper ring
remover
(1) Set valve guide on the opposite side of the

combustion chamber and tap down by using
the valve guide installer, until the height of the
valve guide comes near to the level of the
valve guide installer scale.
(2) Check the part of the valve guide protruding
after assembling.
Standard Height of protruding part above the
cylinder head : 16.5 mm (0.650 in)
Fig 1-30
13. Remove the taper sleeve after compressing the

valve spring by using valve spring lifter and pivot
Diesel Engine D427
16
Engine
Fig 1-33
Fig 1-36
16. Remove the piston pin by using the piston pin

remover & installer.
19. Assemble the piston rings and oil rings onto

piston as shown in the figure.
CAUTIONS :
a) Gaps on the top ring and second ring must be
placed on the opposite side of combustion
chamber.
b) Gap on the top ring should not face thrust side or
counter thrust side.
c) Gap on the top ring should be set on opposite side
(180) of oil ring gap.
Fig 1-34
17. Assemble the piston and connecting rod, after

inserting connecting rod into piston as shown in
the figure.
Fig 1-37
20. Install the piston into cylinder block by using the

piston ring compressor, and make sure that the
piston is placed as shown in the figure. (Install
the piston so that F mark on the piston faces
the front side of the engine).
Fig 1-35
18. Assemble the piston rings after checking that the

Y marked surfaces of the rings appear on the
upper side of the rings.
Diesel Engine D427
17
Engine
Fig 1-39
Fig 1-42
21. Adjust valve clearance after assembling. Oil pan

gasket is composed of side, front and back
gaskets as shown in the figure.
24. Remove the injection pump gear by using the

extractor.
CAUTION : Use new oil pan gasket.
Fig 1-43
25. Install the idling gear with its reference mark

(punched mark) meeting those of other pears.
Fig 1-40
22. Remove the timing gear by using the bearing

puller set
Fig 1-44
26. Insert the oil seal, by using the oil seal puller &
installer timing cover.
Fig 1-41
23. Remove the cam gear by using the timing gear

case cover mounting bolts and bearing puller set.
Diesel Engine D427
18
Engine
Fig 1-45
Fig 1-48
CAUTIONS
a) Position the bearing cap and bearing according to
their numbers.
b) Line up thrust washers upright, and be careful not
to alter bearing combination.
28. Install the cylinder liner, and measure cylinder

inner diameter and height of liner protruding part.
Standard cylinder bore dia :
92.025 ~ 92.050 mm (3.623 ~ 3.624 in )
Protrusion height above cylinder block :
-0.101 ~ 0 mm (-0.004 ~ 0 in)
Fig 1-46
Fig 1-49
27. Remove the cylinder liner, by using cylinder liner

replacer and press.
29. Assemble the main bearing in reverse order of

disassembly carefully not to apply oil on the back
of the bearing.
Cylinder liner assembling pressure :1 ~ 3 tons
30. Apply the grease on crankshaft main journal and

crank pin.
Fig 1-47
NOTES :
a) If cylinder liner is difficult to remove, then bore the
liner until it comes loose.
b) Check for any damage or scratch on the cylinder
bore wall after removing the liner and, if there is
any defect, repair by using fine sandpaper.
Diesel Engine D427
19
Engine
Fig 1-50
Fig 1-53
31. Assemble the main bearing cap, directing arrow

mark on the top of the cap towards engine front.
35. Replacing valve seal

(1) Remove the valve seal by using the suitable
tools.
(2) Insert new seal into valve guide.
(3) Assemble the valve seal by using the valve
seal pusher. Press valve seal pusher until the
valve seal reaches the bottom of valve spring
seat.
32. Assemble the thrust washers on both sides of

center bearing, with their oil grooves facing
outwards.
Fig 1-51
33. Apply engine oil to connecting rod bearing, and

make sure that the weight marks on the
connecting rod and bearing cap meet each other.
Fig 1-52
34. Check to make sure that the end of push rod is

set at the hollow point of the tappet.
Diesel Engine D427
20
Engine
Replacement of Insert

Cylinder Head
Inspection of Cylinder Head
Fig 1-57
Inspect insert for damage and crack. If a problem is

found, replace the part.
Fig 1-55
1. Inspect for distortion, damage and cracks. If a

problem is found, repair or replace the part.
2. Measure cylinder surface (combustion chamber
side) for distortion with straight edge and filler
gauge.
Fig 1-58
1. Romove insert by hitting round steel rod with a

hammer after inserting the round steel rod into
glow plug hole or nozzle holder hole.
Fig 1-56
3. Measure cylinder head for distortion in the six

directions shown in the figure. If cylinder head
distortion exceeds the limit, replace the cylinder
head.
Distortion limit :
A, B : 0.1 mm (0.004 in)
C, D, E, F : 0.25 mm (0.010 in)
Fig 1-59
2. Set the insert at the specified position on cylinder

head, adjust so that it connects with welsh washer.
Set it facing towards cylinder head gasket and set
the welsh washer at its original positon.
3. Tap the center of the welsh washer slightly, to fix it.
Diesel Engine D427
21
Engine
Inspection of Valve and Valve Seat Contact

Surface
Repair of Valve and Valve Seat Surface
Inspect contact surface of valve and valve seat as

follows :
Fig 1-62
1. If the problem is slight, grind the valve with a valve

grinder and compound.
Fig 1-60
1. Apply Prussian blue on contact area of valve seat.

2. Press down valve onto valve seat.
3. Check how Prussian blue adheres to the valve,
and see if it is properly in contact with valve seat.
Inspection of Valve seat Contact Position

Fig 1-63
Check the surface which contacts the valve face. The

valve contact position in relation to the valve seat
must be at the center of the circumference.
2. If the problem is a little serious, repair the valve

seat to the specifid angle with a valve cutter.
Valve seat angle
Intake valve : 45
Exhaust valve : 30
Valve seat contact with :
Intake valve : 2.0 mm (0.079 in )
Exhaust valve : 2.0 mm (0.079 in )
Fig 1-61
Standard valve seat contact width :

2.0 mm (0.079 in)
Diesel Engine D427
22
Engine
Fig 1-64
Fig 1-66
3. Grind the valve, with 3 valve grinder and

compound.
4. Check lenght L before adjusting.
Projection Length of Valve Stem Above Cylinder

Head(Length L)
Measure the projection length of the valve stem above
the cylinder head (lenght L ) and, if more than
standard, adjust according to the following instructions :
Fig 1-67
(2) 0.5mm ~ 1.5mm long

Place a washer (inner dia. 12.8mm, outer dia. 39
mm) under the lower spring seat. Adjust length L
as standard valve.
Standard lenght L 48.05 mm (1.89 in)
(3) 1.5mm above

Replace new one, and then measure length L.
Fig 1-65
(1) 0 ~ 0.5mm long

Use without adjusting.
Diesel Engine D427
23
Engine
Valve
Clearance Between Valve Stem and Valve Guide
Checking Condition
Measure the clearance of max-wear piston between

valve stem and valve guide with a dial gauge, by
turning valve and moving valve stem horizontally.
Fig 1-68
Fig 1-70
Visually inspect the valve for even seating of valve

seat with the center part of the valve, and check for
defect. If any defective part is wide, replace valve
and grind it if defective area is minor.
Clearance limit
Intake : 0.127mm (0.0050 in)
Exhaust : 0.127mm (0.0050 in)
If the clearance exceeds the limit, replace valve and
valve guide.
Dimensions of Valve
Valve Spring
Checking Free Length
Measure uncompressed length with calipers.
Fig 1-69
Fig 1-71
Thickness of head (valve verge)

Standard :
Intake : 1.7 mm (0.0669 in)
Exhaust : 1.5 mm (0.0591 in)
DIA. of valve stem :
Standard:
Intake : 8.955 ~ 8.980mm (0.3526 ~ 0.3535 in)
Exhaust : 8.935 ~ 8.960mm (0.3518 ~ 0.3528 in)
Limit :
Intake : 8.904mm (0.3506 in)
Exhaust : 8.884mm (0.3498 in)
Diesel Engine D427
Uncompressed length limit

Outer spring : 52.9 mm (2.083 in)
Inner spring : 42.0 mm (1.654 in)
Replace the spring if shorter than uncompressed
length limit.
24
Engine
Checking Tension
Push Rod
Measure tension of assembled valve spring by using

valve spring tester.
Checking Condition
Fig 1-74
Fig 1-72
1. Place valve spring on a valve spring tester.
Inspect both ends of push rod for wear or damage,

and replace if necessary.
2. Compress the valve spring to assembled lenght.

(Compress several times).
Checking Deflection
3. Measure the spring tension when the spring is

compressed longitudinally.
Spring
Assembled length
Standard, tension
of assembled spring
Allowable tension
Outer spring 40.3 mm(1.587 in) 18.0 L 0.9kg(39.7 L 2.0 lb)
15.9kg(35.1 lb)
37.8 mm(1.488 in) 12.7 L 0.6kg(28.0 L 1.3lb)
11.3kg(24.9 lb)
Inner spring
Place the push rod on a plane surface, and measure

the clearance between the plane surface and rod
with feeler gauge.
Checking Perpendicular
Place the spring on a surface, and measure the
variation form perpendicular at the top of the spring.
Fig 1-75
Deflection limit : 0.19 mm (0.075 in)

If the deflection exceeds the limit straighten or
replace.
Fig 1-73
Angle limit
Outter spring : 1.37mm (0.0539 in)
Inner spring : 1.25 mm (0.0492 in)
Diesel Engine D427
25
Engine
Tappet
Rocker Arm
Checking Condition
Checking Condition
Fig 1-78
Fig 1-76
Inspect tappet for crack or damage, and replace it if

necessary. Inspect contact point with came, and
replace it if it is worn out.
1. Inspect every part of rocker arm assembly for

crack or damage, and replace it if necessary.
2. Inspect oil holes of rocker arm and shaft, and
clean them if blocked.
Checking of Clearance Between Tappet and

Tappet Guide
Checking Clearance
Fig 1-77
Fig 1-79
Measure the clearance between tappet and tappet

guide, and replace tapper or cylinder block if the
clearance exceeds the limit.
Measure the clearance between rocker arm shaft and

rocker arm bushing with a dial gauge.
Clearance limit : 0.07 mm (0.0028 in)
Replace the rocker arm shaft and bushing, if the

Diesel Engine D427
26
Engine
Replacement of Rocker Arm Bushing
Piston and Piston Ring

Checking Condition
Fig 1-80
Fig 1-82
1. Inspect sliding surface, ring groove, and other

parts for crack or damage, and replace if
necessary.
2. Inspect for breakage, burning, wear and other
defects on the rings, and replace if necessary.
Fig 1-81
1. Remove the bushing by using press and round

steel rod of proper diameter.
2. Press into the bushing by aligning the oil hole of
rocker arm bushing.
3. Bore the bushing by using expansion reamer and
pin hole grinder, in order to be within standard
clearance between bushing and shaft after
installing.
Standard clearance :
0.016 ~ 0.061 mm (0.0006 ~ 0.0024 in )
Diesel Engine D427
27
Engine
Checking Clearance
Checking Piston Ring end Gap

Measure piston ring end gap after inserting piston
ring into a cylinder liner.
Fig 1-83
Fig 1-85
(1) When reusing the piston ring :

Measure the gap, placing the ring at the point
where the cylinder liner is most worn.
(2) When replacing the piston ring :
Measure the gap, placing the ring at the point
where the cylinder liner is least worn.
End gap limit : 1.5 mm (0.059 in)
Fig 1-84
Measure the clearance between piston and cylinder

liner, and replace piston or cylinder liner if the
Checking clearance Between Piston Ring Groove

and Piston Ring
Piston and cylinder liner clearance limit :

0.044 ~ 0.070 mm (0.0017 ~ 0.0028 in)
Measure the piston outer diameter in the thrust
direction, 18mm (0.71 in) above the bottom of piston.
Standard piston outer diameter :
91.967 ~ 91.993mm (3.621 ~ 3.622 in)
Fig 1-86
1. Install the piston ring into the piston.

2. Measure clearance between piston ring groove
and piston ring with a filler gauge. Replace piston
or piston ring if the clearance exceeds the limit.
Diesel Engine D427
28
Engine
Connecting Rod
Checking end Play of Big end
Checking Condition
Check end play of the big end of the connecting rod,

and replace connecting rod or crankshaft if the play
exceeds the limit.
Fig 1-87
Fig 1-89
Inspect connecting rod at both ends for crack of

damage on the surface, and replace it if necessary.
1. Fit connecting rod to crankshsft.

2. Measure end play by using a dial gauge with
magnetic base.
Checking for Bending & Torsion
End play limit : 0.40 mm (0.016 in)
Checking Clearance Between Piston Pin and

Bushing
Fig 1-88
Check for banding or torsion of connecting rod by

using connecting rod aligner, and modify the
connecting rod with a press, replace it.
Bending limit : 0.05 mm (per 100mm)
Fig 1-90
Measure the clearance between piston pin and

bushing as shown in the figure, and replace piston
pin or bushing if the clearance exceeds the limit.
Diesel Engine D427
29
Engine
Replacement of Small end Bushing
Fig 1-93
Fig 1-91
When grinding the bushing make sure that the

reamer is precisely inserted to prevent a rough
bushing surface always grind in the direction of
cutting. Always be sure not to stop the reamer at
same points. When repairing the small end bushing
with a pin hole horning machine, the bushing hole
tends to incline to one direction, so change the
connecting rod position many times during the
horning process until horning size reaches standard.
1. Replace the bushing by using a rod and press.
Connecting Rod Bearing

Checking Condition
Fig 1-92
2. Push the bushing with a press, confirming that the

oil holes of connecting rod and bushing are in
alignment with each other.
3. Adjust bushing hole with a reamer so that the
clearance between piston pin and bush is within
standard.
Standard clearance :
0.014 ~ 0.044 mm (0.0006 ~ 0.0017 in)
Fig 1-94
Check connecting rod bearing for burning, melting

and other damage, and replace if necessary.
Diesel Engine D427
30
Engine
Checking Clearance
Crankshaft
Measure the oil clearance between crankshaft journal

and connecting rod bearing with a plasti-gauge, in
the follwing order.
Checking Condition
Fig 1-96
Fig 1-95
1. Inspect the crankshaft for crack, breakage, or

other damage, and replace it if necessary.
1. Remove oil residue from joural and bearing.

2. Check if oil holes are clogged, and unblock them
by using compressed air or a needle if clogged.
2. Set plasti-gauge to axial direction on a journal.

3. Install bearing cap and tighen to the specified torque.
Checking Wear
Cap bolt tightening torque :

7.6 ~ 8.3 mkg (55.0 ~ 6.0 ftlb)
4. Measure the clearance by using the plastigauge
after removing the cap.
Oil clearance
Standard : 0.059-0.090 mm (0.0023 ~ 0.0035 in)
Limit : 0.12 mm (0.0047 in)
If the oil clearance exceeds the standard value, grind
the crank pin use undersized bearing.
Fig 1-97
1. Inspect the crankshaft for wear.

2. Inspect crankshaft pin and main journal in all
directions (front and rear, diagonal directions), and
if wear and tear of the crankshaft is beyond
allowance limits, grind it to undersize and use
undersized main bearing.
Diesel Engine D427
31
Engine
Checking Deflection
Main Bearing
Checking Condition
Fig 1-98
Fig 1-100
1. Place and secure both ends of the crankshaft on

V-blocks.
Check the main bearing for wear, melting and other

damage and replace it if necessary.
2. Measure the deflection by placing a dial gauge on

the center of main journal and crankshaft slowly.
Replace crankshaft if the value exceeds the limit.
Read the maximum value on the dial gauge.
Checking Clearance
Checking end Play
Fig 1-101
Measure oil clearance between main journal and

main bearing by using plasti-gauge.
Fig 1-99
Oil clearance
Standard : 0.059 ~ 0.090 mm (0.0023 ~ 0.0035 in)
Limit : 0.12 mm (0.0047 in)
Measure crankshaft end play by placing a dial gauge

on crankshaft rear end and by moving crankshaft
back and forth in the axial direction. If the value
exceeds the limit, replace the thrust washer, which is
inserted to the center bearing with 0.718 mm
oversized one.
If oil clearance exceeds the limit, grind the main

jounal and use the undersized bearing.
End play
Standard : 0.14 ~ 0.39 mm (0.0055 ~ 0.0154 in)
Limit : 0.4 mm (0.016 in)
Diesel Engine D427
32
Engine
Cylinder Block
Cylinder Liner
Checking Condition
Checking Wear
Measure the inner diameter of cylinder liner, and
check for wear, and its extent. Measure the inner
diameter at 3 positions, of top, middle and buttom at
sections X-X, and Y-Y, as shown in the figure
Fig 1-102
1. Inspect the cylinder block for crack, breakage,

damage or other defects, and repair or replace if
necessary.
Fig 1-104
2. Check if oil holes and coolant passages are

clogged, and pierce with compressed air or
needles as necessary.
Wear limit
Wear=Measured highest value-Standard highest
value
Standard cylinder liner :
92.025 ~ 92.050 mm (3.623 ~ 3.624 in)
Checking Distortion
Fig 1-103
Fig 1-105
Measure the distortion of top surface of the cylinder

block, and repair or replace if the distortion exceeds
the limit.
If the wear exceeds 2.0 mm ( 0.079 in), replace the

cylinder liner.
Distortion limit
A B : 0.10 mm (0.004 in)
C D : 0.25 mm (0.010 in)
Diesel Engine D427
one-sided wear limit

One-sided wear=Measured highest value Measured lowest valve
If the one-sided wear exceeds 2.0mm (0.079 in),
replace the cylinder liner.
33
Engine
Camshaft
Checking The Cam Journal Wear
Checking Condition
Check the cam jounal for wear, and replace the cam
shaft if the wear exceeds the limit.
Inspect camshaft for crack, breakage, damage of

other defects, and replace it necessary.
Fig 1-108
Fig 1-106
Journal Diameter
1. Repair for replace if necessary.
No.1
2. Be careful not to change the original shape of the

cam when repairing.
51.910-51.940mm
2.044 - 2.045 in)
No.2
51.660-51.690mm
(2.034-2.035 in)
No.3
51.410-51.440mm
(2.24-2025 in)
No.4
51.160-51.190mm
(2.014~ 2.015)
Checking Height
Wear
limit
0.008mm
(0.0003 in)
Checking Deflection
Fig 1-107
Check the height of the cam, and replace if lower

than minimum height.
Cam height limit : (42.478 mm) (1.672 in)
Fig 1-109
Minor cam surface defects can be repaired by using

a fine abrasive compound, but be careful not to
change the original of the cam when repairing.
Support both ends of the camshaft with V-blocks.

Measure in deflection with dial gauge on journal by
turning the camshaft slowly. If the deflecetion
exceeds the limit, replace the camshaft.
Diesel Engine D427
34
Engine
Checking end Play
Gears(Cam Shaft Gear, Idling Gear,

Cam Gear, Injection Pump Gear)
Checking Condition
Fig 1-110
Measure the end play, and replace thrust plate if the

value exceeds the limit.
Fig 1-113
1. Mount thrust plate and camshaft gear on

camshaft.
Replace gear if the gear teeth have been cracked or

damaged.
2. Tighten the lock bolt to the specified torque.

Checking Backlash
Bolt tightening torque :

6.2 ~ 7.0 mkg (44.8 ~ 50.6 ftlb)
End play limit : 0.3 mm (0.012 in)
Measure backlash between idling gear and other

gears with a dial gauge.
Backlash
Standard : 0.10 ~ 0.17 mm (0.004 ~ 0.007 in)
Limit : 0.3 mm (0.012 in)
Checking Journal Oil Clearance
Checking Idle Gear end Play
Fig 1-111
Check the oil clearance by measuring inner diameter

of camshaft bearing, and outer diameter of cam
journal. If the oil clearance exceeds the limit, replace
the camshaft or cylinder block.
Fig 1-114
Measure the end play by inserting a filler gauge

bewteen idling gear and thrust.
Oil clearance limit : 0.145 mm (0.006 in)
Standard end play :

0.15 ~ 0.28 mm (0.006 ~ 0.011 in)
Diesel Engine D427
35
Engine
Checking Oil Clearance Between Idling Gear and

Spindle
Oil Seal (Timing Gear Cover Oil

Seal, Rear Oil Seal)
Checking
Fig 1-115
Measure the oil clearance by checking inner diameter

of idling gear and outer diameter of spindle. If the oil
clearance exceeds limit, replace idling gear bushing
and spindle.
Fig 1-116
Oil clearance
Standard : 0.034 ~ 0.048 mm(0.001 ~ 0.003 in)
Limit : 0.15 mm (0.06 in)
Fig 1-117
Inspect oil seals for wear, breakage and damage,

and replace defective oil seals.
Diesel Engine D427
36
Engine
Lubrication System
Outline
Structural View
Fig 2-1
Diesel Engine D427
37
Lubrication Systems
Specifications
Lubrication System
Oil pump
Force-feed type
Type
Trochoid type
3.8 kg/cm2(56.9 lb/in2)
Oil pressure control valve opening pressure

Oil Filter
Type
Full-flow type, paper filter
Oil filter relief valve opening pressure

Oil cooler
0.8~1.2kg/cm2(11.4~17.1 lb/cn2)
Type
water cooled type

0.2~0.4kg/cm2(2.8~5.7 lb/in2)
Oil warning lamp activation pressure
Preblem
Possible Cause
Remedy
OIl leakage
Loose drain plug

Faulty seal oil and cylinder block
Damaged cylinder head cover
Loose oil pump body bolt, cylinder head cover bolt, or oil pan bolt
Damaged front housing gasket, or cylinder head gasket
Faulty oil seal(s)
Loose oil filter
Loose or damaged oil pressure switch
Tighten or replace
Replace
Replace
Tighten
Replace
Replace
Tighten
Tighten or replace
Oil pressure drop
Oil leak
Insufficient oil
Worn and/or damaged oil pump gear
Worn plunger(inside oil pump) or weak spring
Clogged oil strainer
Excessive lubrication clearance between main bearing and
connecting rod bearing
As described above
Add oil
Replace
Replace
Clean it
Oil pressure drop

Malfunction of oil pressure switch
Problem in electrical system
As described above
Repair
Repair
Warning lamp
illuminates while
engine running
Diesel Engine D427
38
Refer to Group 1
Lubrication Systems
Inspection
Oil Pump
Checking Oil Pressure
Rremoval and Installation

Remove each part in the following order, lnstallation
is the reverse order of removal.
1. Drain engine oil.
2. Remove the oil pan.
3. Remove the oil pipe.
4. Remove the oil pump.
Fig 2-2
Disassembly
1. Remove the oil pressure switch.
Disassemble in the following sequence :
2. Mount the oil pressure gauge on the cylinder block
hole where oil pressure switch had been installed.
3. Start the engine and warm it up to an appropriate
temperature.
4. Read the gauge, holding the engine speed
steady(High idle).
Oil pressure limit : 3.8kgcm2 (54.1 lbin2)
IF the oil pressure exceeds the limit, each part and
repair if necessary.
FIG 2-3
(1) Oil pump body. (2) Set screw. (3) Nut. (4) Plunger.
(5) Spring. (6) Plug. (7) Drive shaft. (8) Outer rotor
(9) Inner rotor. (10) Cover. (11) Oil strainer. (12) Oil pipe
Diesel Engine D427
39
Lubrication Systems
Clearance Between Outer Rotor and Pump Doby
Inspection
Checking Condition
Check all parts visually, and replace if necessary.
Carefully check the sliding surface of the pump
cover, and replace if significantly of the pump cover,
and replace if significantly defective (Repair minor
defects by grinding with grinding compound).
Clearance Between Pump Body And Shaft

Fig 2-7
Measure clearance between outer rotor and pump

body with a leaf gauge. If the clearance exceeds the
limit, replace the rotor or pump body.
Clearance Between Rotor and Pump Cover

Fig 2-5
Measure the clearance with a dial gauge and

magnetic base.
If the clearance exceeds the limit, replace the pump
drive shaft, inner rotor, pump body and drive gear.
Fig 2-8
Clearance Between Inner and Outer Rotor
Check the end float of the rotor. Place a flat ruler

across the pump body and measure the clearance
between ruler and rotor. If the clearance exceeds the
limit, replace the drive gear, drive shaft, inner rotor,
outer rotor and pump body.
Free Length of Plunger Spring

Check wear of relief valve plunger and spring defect.
Fig 2-6
Free length of spring : 40 mm (1.57 in)
Measure the clearance with a leaf gauge. Replace

both rotors if the clearance exceeds the limit.
Diesel Engine D427
40
Lubrication Systems
Assembly
7. Remove the gasket.

8. Remove the level switch from the oil pan (if
installed).
9. Remove oil level gauge pipe from the oil pan
upper bock.
Installation
Install in the reverse order of removal
Fig 2-9
CAUTION : Install oil pan upper block with its

assembly surface conforming to the cylinder block
under part.
Assemble in reverse order of disassembly.

CAUTION : When assembling the rotor on the body,
confirm that the matching marks are in the front of
the cover.
Replace the oil pan gasket with a new one. Apply a

thin coating of engine oil to gasket between the
cylinder block and the oil pan. Tighten the oil pan
bolts and nuts on the cylinder block to the specified
torque.
Cover tightening torque :

0.8 ~ 1.2 mkg (5.79 ~ 8.68 ftlb)
Tightening torque : 1.6 ~ 2.3 mkg (11.6 ~ 16.6 ftlb)
Oil Pan
Inspection
Removal
1. Remove dust and chips from oil pan.

2. Inspect the oil pan for cracking, and check the
drain plug spiral part for damage. Check bolt hole
for any damage due to excessive tightening.
Repair such damaged part, and replace if difficult
to repair.
Fig 2-10
1. Drain engine oil.

2. Remove the hose between the vacuum pump and
the oil pan upper block.
3. Remove the oil level gauge pipe from the rubber
hose.
4. Remove the oil level switch coupler (if installed).
5. Remove the oil pan.
6. Remove the gasket.
Diesel Engine D427
41
Lubrication Systems
Cooling System
Specifications
Cooling Method
Water-cooled
Type
Wax type(2 stage)
Opening temp
82 L 1.5C
Full-open temp
95C
Full-open lift
8.0mm (0.31 in) or more
Water pump type
Type
Centrifugal, timing belt driven
Radiator
Type
Corrugated
1.0 L 0.15 kg/cm2(14.2 L 2.1 lb/in2)
Cap valve opening pressure
Preblem
Possible Cause
Remedy
Water leakage
Damaged radiator core seam

Leakage from radiator hose or heater hose
Leakage from water temperature switch
Leakage from water seal (water pump)
Damaged or loose thermostat cover or gasket
Loose cylinder head bolt
Damaged cylinder block
Cracked cylinder head
Replace
Repair or replace
Repair or replace
Replace
Repair or replace
Tighten
Replace
Replace
Corrosion
Impurities in coolant
Clean
Overheating
Water passage clogged

Thermostat malfunction
Radiator fins clogged
Water pump malfunction
Insufficient coolant
Thermo - modulated cooling fan malfunction
Radiator cap malfunction
Clean
Replace
Clean
Repair or replace
Add
Replace
Replace
Diesel Engine D427
42
Cooling System
Inspection
Thermostat
Removal
Remove the thermostat in the following sequence.
Fig 3-11
Put the thermostat and a thermometer in water, heat

the water temperature gradually and raise the
temperature, both when the thermostat valve starts to
open and when it is fully open. If the temperature
values are lower than the specified values, replace
the thermostat.
Fig 3-9
Opening temp
Full-open temp
Full-open lift
82C L 1.5C
95C
8mm(0.3in) or more
Installation
Install the thermostat in the reverse order of removal.
Notes
Fig 3-10
1. Remove the coolant. Drain the coolant until the

coolant level drops below the thermostat case.
2. Remove the radiator upper hose.
3. Remove the thermostat.
Fig 3-12
a) Replace the gasket whenever installing the

thermostat cover.
b) Set the thermostat with its air hole on top.
c) After installing the thermostat, fill the coolant, start
the engine, and check for any leakage.
Diesel Engine D427
43
Cooling System
Water Pump
Disassemble in the numbered sequence shown in

the figure, and assemble in reverse order of
disassembly.
On-Vehicle Inspection
Fig 3-13
Check the water pump for leakage, noise and

looseness to the shaft or bearing. Clattering noise,
when the fan blades are pushed up and down,
indicates that the bearing is worn-out and defective,
in the hole of pump body is leaking, disassemble
hole of the pump and replace the seal.
Fig 3-15
Removal and Installation
(1) Nut & washer. (2) Bearing housing. (3) Gasket.

(4) Pulley boss. (5) Snap ring.
(6) Shaft, spacer & bearing ass'y. (7) Impeller. (8) Seal ass'y.
(9) Bearing. (10) Spacer. (11) Bearing. (12) Baffle plate.
(13) Dust seal. (14) Snap ring.
Remove the water pump in the numbered order.

Installation is the reverse order of removal.
Fig 3-14
Fig 3-16
1. Drain the coolant.

1. Remove the pump pulley boss with the fan pulley
boss puller and press.
2. Remove the radiator cowling.

3. Remove the cooling fan.
4. Remove the V-belt.
5. Remove the cooling fan pulley.
6. Remove the water hose.
7. Remove the water pump.
Diesel Engine D427
44
Cooling System
Inspection
Fig 3-17
2. Remove the impeller and the shaft from bearing

housing by using the support block and press.
Fig 3-20
1. Disassemble scale from within the pump body.

Clean removed parts.
2. Inspect all pump parts, and replace any part which
is cracked or damaged.
3. Check the water pump for noise and looseness,
and replace if necessary.
4. Always use a new water seal after disassembling
the water pump. Replace the impeller if there are
defects in water seal and impeller contact surface.
Fig 3-18
V-belt
3. Remove the snap ring by using snap ring pliers,
and push out the water pump shaft from the
bearing.
Inspection
Fig 3-21
Fig 3-19
1. Check the V-belt for breakage or wear, and

replace if necessary.
4. Apply or inject grease to the following parts :

CAUTIONS :
a) Fill 1/3 of the bearing space with lithium grease
(NLGI NO2).
b) Apply grease on water seal surface contacting the
impeller.
2. If there is any noise, check tension of the belt and

alignment of the pulleys.
3. V-belt should depress by a given amount when
10kg power is applied to it.
Belt deflection
New belt : 10 ~ 12 mm (0.39 ~ 0.47 in)
Used belt : 13 ~ 16 mm (0.51 ~ 0.63 in)
Diesel Engine D427
45
Cooling System
Fuel System
Outline
Structural View
Fig 4-1
Diesel Engine D427
46
Fuel Systems
Specifications
Item
Specification
Injection pump
Injection nozzle
Type
VE type
Injection timing
ATDC 2
Turning direction
Clockwise
Idling speed
1100 L 25
Nozzle type
Throttle type
Orifice Dia. XNo.
8mm (0.032 in.)X1
Injection pressure
135~140 kg/cm2
Air cleaner
Filter paper element type
Fuel Filter
Cartridge type with water-detector
Injection order
1-3-4-2
Preblem
Hard starting
Possible Cause
Remedy
Clogged fuel filter

Air in fuel filter
Faulty fuel cut valve
Faulty injection timing
Air in injection pump
Trouble inside of injection pump
Seized needle valve of injection nozzle
Fuel dripping from injection nozzle
Faulty cold start device
Replace
Air-bleed
Replace
Adjust
Air-bleed
Replace
Clean or replace
Adjust
Adjust or replace
Rough idling
Clogged fuel filter

Air in fuel filter
Trouble inside of injection pump
Faulty injection starting pressure
Improper mounting to nozzle holder
Leakage at gasker
Crack in injection pipe
Leaking from injection pipe joint
improper idling speed
Replace
Air-bleed
Replace
Adjust
Air-bleed
Replace
Clean or replace
Adjust
Disassemble and assemble or replace
Replace
Replace
Retighten or replace
Adjust
Engine knocking

Low quality fuel
Adjust
Replace
Adjust
Clean or replace
Replace
Engine knockin

Low quality fuel
Adjust
Replace
Adjust
Clean or replace
Replace
Diesel Engine D427
47
Fuel Systems
Preblem
Possible Cause
Remedy
High fuel consumption

High idling speed
Leakage of gasket
Clogged fuel filter
Clogged air cleaner
Adjust
Adjust
Adjust
Replace
Replace
Replace
Clean or replace
Poor acceleration
Clogged air cleaner

Fuel dripping form injection nozzle
Trouble inside of pump
Crack of injection pipe
Air in fuel filter
Clogged fuel filter
Clean or replace
Clean or replace
Replace
Replace
Adjust
Air-bleed
Replace
Replace
Air-bleed
replace
Excessive
exhaust smoke
Clogged air cleaner

Improper injection timing
Faulty injection nozzle
Clean of replace
Adjust
Adjust or replace
Diesel Engine D427
48
Fuel Systems
Fuel Filter
Air Bleeding
Fig 4-7
Fig 4-9
The fuel filter is installed between the fuel tank and

the injection pump, and it filters out all impurities from
the fuel system.
Fig 4-10
1. Loosen the air breather on the fuel filter.

2. Operate the priming pump in the fuel filter until the
pure fuel comes out.
3. After bleeding all the between fuel tank and fuel
filter, fuel comes out.
Fig 4-8
4. Loosen the overflow pipe of injection pump.

Remove as the following sequence. Install the filter in
the reverse order of removal.
5. Supply fuel to pump compartment in the injection

pump by operating the priming pump.
1. Drain fuel from the filter.

6. Start the engine, and bleed air in the injection
pump.
2. Remove the element, sealing, 0-ring and bow

downwards from the body.
7. Tighten the overflow pipe connector.

NOTE: Apply fuel to the sealing (top & base) and
0ring-before installing.
8. Loosen the injection pipe on injection nozzle side.

9. Start the engine and check whether fuel us is
being ejected from injection pipe
After installing the filter, remove the air breather

screw in order to remove air with the priming the
filter, remove the air with priming pump, and after
starting the engine, check for leakage
Diesel Engine D427
49
Fuel Systems
Water-Drain
Replacement
1. When removing the fuel filter, be careful not to
spoil the fuel by holding the fuel filter upright.
Fig 4-11
Drain water when indicating lamp comes on or when

float level reaches standard level.
1. Loosen the drain plug.
2. Loosen the air breather if water does not come out
easily.
3. After draining water, supply fuel by operating the
priming pump on the filter.
4. DO air-bleeding.
Fig 4-12
(1) Adapter. (2) Cartridge. (3) Level sensor. (4) Drain plug
(5) Air breather.
2. Apply a small amount of diesel on the packing.

3. Install the cartridge to adapter and tighten securely
by hand.
4. Install the sensor and drain plug to the cartridge.
5. Bleed air in the filter.
6. Start the engine and check whether there is any
leakage.
Diesel Engine D427
50
Fuel Systems
Injection Pump
If the inside of the injection pump is disassembled for
maintenance, be sure to properly use the checking device
such as the injection tester, and carefully inspect each
component.
Structural View
Fig 4-13
Diesel Engine D427
51
Fuel Systems
Checking Injection Timing
On-Vehicle Inspection and

Adjustment
Checking Idling Speed
1. Warm up the engine.
2. Put the tachometer
3. Idle the engine.
4. Check the engine speed.
Fig 4-17
5. Adjust the idling-speed if the idling speed a with

the specified range.
1. Disconnect the fuel injection pipes from the

injection pump.
Standard idling speed : 1100 L 25
2. Remove the bolt and gasket from distributor head

of the injection pump.
Adjusting Idling Speed
Fig 4-18
Fig 4-16
3. Mount the measuring device on the injection

pump. Make sure that the tip of the tester feeler
needle touches the plunger end of pump.
1. Confirm the accelerator cable deflection. If the

deflection is not suitable, adjust it by turning
accelerator cable lock nuts.
2. Loosen the lock nut of the idle adjusting bolt and
adjust the idling speed by turning the idle adjusting
bolt.
NOTE : Idle speed will increase when the adjusting
bolt is turned clockwise and decrease when turned
counter-clockwise.
3. After adjusting, press the accelerator pedal 2 ~
3times, and check the return of the accelerator
cable
Fig 4-19
4. Set the flywheel ring gear BTDC 30 and find a

position where the pointer of dial gauge fixed.
5. After confirming the stability of the dial gauge
pointer, set the dial gauge pointer to O point.
Diesel Engine D427
52
Fuel Systems
Removal
Fig 4-20
6. Turn the flywheel clockwise until indicator pointer

comes to TDC. The injection timing is right if the
pointer is increased 1mm.
Fig 4-22
Cam lift at optimal injection timing :

1.00 mm (0.039 in)
7. Adjust injection timing if the cam lift exceeds 1mm.
Adjusting Injection Pump
Fig 4-23
1. Remove the (+) (-) terminals from the battery.

2. Remove the upper cover and the cooling fan.
3. Disconnect the air hose.
4. Disconnect the fuel pipe and the injection pipe.
5. Remove the accelerator cable from the injection
pump.
Fig 4-21
1. If the injection timing is not correct, turn the

injection pump, and set at a position where the dial
gauge pointer indicates 1.00 mm (0.039 in).
6. Remove the fuel-cut solenoid wire.l

7. Remove the injection pump cover.
If the cam lift value is more than 1mm, adjust so

that the cam lift becomes 1.00mm, by turning the
injection pump one full turn clockwise(in direction
of engine rotation) and counter-clockwise it as
necessary again.
If the cam lift is less than 1mm, adjust the cam
lift by turning the injection pump counterclockwise.
8. Loosen the lock nut.

9. Remove the plane washer. Be sure not to drop the
washer into the gear case by using a wire.
10. When checking the shaft key of the injection
pump, turn the flywheel through the timing hole
on the clutch cover until the key arrives at the
position.
2. After adjustment, install the gasket and tighten the

head bolt.
NOTE : When adjusting, use a new head bolt and
gasket.
Diesel Engine D427
53
Fuel Systems
Installation
Install the injection pump in the reverse order of
removal, paying attention to the following points :
Fig 4-24
11. Remove the bolt on the auxiliary bracket, which

fixes the lower part of the injection pump.
12. Remove the injection pump mounting nut. Also
remove the spring washer and flat washer.
Fig 4-26
1. Before installing the key on the drive shaft of

injection pump, tap the key hole slightly until the
key is inserted into the key hole completely.
13. Remove the pump shaft and the gear.

Set the extractor and use M marked side of it.
Disconnect the shaft and the gear by tightening
extractor bolt.
2. Remove air after installing the injection pump.

Drive gear tightening torque :
4.0 ~ 7.0 mkg (28.9 ~ 50.6 ftlb)
Air-Bleeding
Make sure to bleed the air replacing the fuel filter or
cleaning the sedimenter.
1. Loosen the air bolt on fuel filter.
2. Pump with feed pump until fuel comes out.
Fig 4-25
3. Tighten the air bolt with pressing the feed pump.

14. Remove the injection pump. Remove the injection
pump in turn by pushing other pump gear near to
it, being careful not to drop the key into gear
case.
15. Remove the extractor.
Diesel Engine D427
54
Fuel Systems
Removal
Injection Nozzle(KCA Type)
Remove the injection nozzle in the following order :
Structural View
Fig 4-28
1. Fuel injection pipe

2. Fuel leak pipe lock nut
3. Fuel leak pipe
4. Injection nozzle
5. Washer

Checking Injection starting pressure
Fig 4-27
(1) Nozzle holder body. (2) Pressure Pin. (3) Pressure Spring.
(4) Retaining Nut. (5) Distance Piece. (6) Shim. (7) Washer.
(8) Nut. (9) Nozzle.
Fig 4-29
1. Set the nozzle on the nozzle tester.

2. Bleed the air by pumping the nozzle tester handle
several times.
3. Slowly lower the nozzle tester handle, and check
the value shown on the pressure gauge when
injection is started.
Injection starting pressure :
135 ~ 140 kgcm2 (1920 ~ 1991 lbin2)
Diesel Engine D427
55
Fuel Systems
Checking Atomizing Condition
Fig 4-30
Fig 4-32
4. If the injection starting pressure is not within the

specified range, adjust the starting pressure with
the shim. The shim has 20 different thicknesses
for every 0.05mm (0.0020in.) to 1.95mm
(0.0768in.). As 0.05mm (0.0020in.) is added,
approx. 5kgcm2 (71.12 lbin2) of injection pressure
increases.
1. Set the injection nozzle on a nozzle tester.

2. Bleed the air by operating the nozzle tester handle
several times.
3. Keeping the pressure gauge of the nozzle tester in
the non-functioning condition, quickly lower the
handle several times (lower the handle as quickly
as possible so that a pulsation whistling sound can
be heard) and check the atomizing condition.
Checking Tightness of Valve Seat
(1) Fuel is atomized uniformly and properly.

(2) The injection angle and direction are normal. If
the atomizing condition is incorrect, it is
necessary to disassemble, wash and recheck
the injection nozzle, or to replace it.
Checking Nozzle Valve and Needle Valve

Fig 4-31
Apply a pressure of 115kgcm2 (1635.3 lbin2), and

check for fuel leaks from the nozzle injection hole. If
fuel leaks, it is necessary to disassemble, clean and
recheck the injection nozzle or replace it.
Fig 4-33
1. Check and ensure that the valve seat of the

needle valve and other parts are not damaged.
2. Make sure that the nozzle body is not damaged.
Hold the nozzle body upright and insert
approximately two thirds of the needle valve and
see if the needle valve drops to the valve seat by
its own weight.
Diesel Engine D427
56
Fuel Systems
Assembly
Pay attention to the following matters when
assembling injection nozzle.
Fig 4-34
CAUTIONS :
a) After assembling the injection nozzle, check the
injection starting pressure and atomizing condition.
b) Tighten the nozzle body on the nozzle holder to
the specified torque.
Nozzle tightening torque:
8 ~ 10 mkg (58 ~ 72 ftlb)
Installation
Install in reverse order of removal.
Fig 4-35
CAUTIONS :
a) The gasket and corrugated gasket and not be
reused.
b) Tighten the injection nozzle on the cylinder head
to the specified torque.
Nozzle tightening torque :
6 ~ 7 mkg (43 ~ 52 ftlb)
Diesel Engine D427
57
Fuel Systems

Specifications
Item
Specification
Voltage
12V, Negative Ground

Type
Alternator
Alternating
Output
12V-60A
Regulator Type
Starter
Transistorized(built-in IC regulator)
Type
Electromagnetic push-in-type
Output
12V-2.5kW
Type
Glow plug
Sheathed type
Voltage
11V
Amperage
52A
Preblem
Possible Cause
Remedy
Starter does not

turn at all, or its
turning speed is
too slow to start
the engine.
Battery and related parts

Poor contact of battery terminals
Clean and tighten
Poor grounding of negative cable
Clean and repair
Voltage drop caused by discharged battery
Recharge
Insufficient voltage caused by battery malfunction
Replace
Magnetic switch and related parts
Loose wiring and / or connectors
Repair
Burnt magnetic switch contact plate or improper contact
Replace
Broken wire in magnetic switch contact plate or improper contact Replace
plate or improper contact
Broken wire magnetic switch holding coil
Replace
Starter and related parts
Adjust contact or replace
Poor contact of brushes
Fatigued brush spring
Replace
Poor grounding of field coil
Replace
Poor soldering of field coil
Repair
Commutator malfunction
Repair
Grounded armature
Replace
Worn parts
Replace
Starting problem
Insufficient battery capacity
Recharge
Starter turns but

pinion gear does
not mesh with
ring gear
Tip of overrunning pinion is worn

Fatigued overrunning clutch drive spring
Overrunning clutch races
Improper sliding of spline
Worn bushing
Worn ring gear
Replace
Replace
Replace
Adjust contact and repair
Replace
Replace
Starter turns
continuously
(does not stop)
Sticking contact place of magnetic switch

Layer shorting of coil magnetic switch
Replace
Replace
Diesel Engine D427
58
Preblem
Possible Cause
Remedy
Misfiring of motor
Malfunction of wiring, or poor wiring contact
Replace
Discharging of
battery
Loose drive belt

Grounded or broken stator coil
Broken rotor coil
Poor contact of brush and slip ring
Malfunction or rectifier
Malfunction of IC regulator
Insufficient or unsuitable battery electrolyte
Malfunction of battery electrode(internal short-circuit)
Poor contact of battery terminals
Excessive electric load
Adjust
Replace
Replace
Clean or replace
Replace
Replace
Adjust
Replace
Clean and tighten
Check power consumption
Overcharging
of battery
IC regulator malfunction
Operating in extremely high temperature
Replace
Repair
Diesel Engine D427
59
Removal
Starter
1. Disconnect the battery (-) and (+) terminals.
2. Disconnect the wiring from the starter.

3. Remove the fixing bolts and remove the starter.
Installation
Install the start in the reverse order of removal, taking
care of the following.
1. Tighten terminals B and M to the specified torque.
Fig 5-5
Tightening torque :
8.0 ~ 10.0 mkg (57.9 ~ 72.3 ftlb)
1. Turn off the ignition switch and place the gear shift
lever to neutral position before inspection.
Free Running Test
2. Directly connect the battery terminal B and starter

terminal M.
3. The starter is functioning properly if it turns
smoothly, without abnormal noise.
WARNING
Be specially careful, when the starter is operated,
the engine may start.
Fig 5-7
Measure the current when the start begins to run

constantly connecting the battery, starter and
ammeter as shown in the figure.
Current : 200 A or less
Voltage : 11 V
Fig 5-6
4. If starting is slow, if the starter doesnt turn, or if

abnormal noise is heard, remove the starter and
check it, but be sure to check the following matters
before removing it.
A. Charging condition of battery
B. Looseness or corrosion of battery terminal
C. Condition of ignition switch
E. Locked engine.
Diesel Engine D427
60
Disassembly
Fig 5-8
Diesel Engine D427
61
Inspection
Checking the Armature
Fig 5-11
5. Measure the shrinkage of the mold between

segments. If the value is 0.2mm (0.008 in) or less,
undercut by 0.5 to 0.8mm (0.02 ~ 0.03 in).
Fig 5-9
1. Check insulation between all segments and core

of the armature coil.
Field Coil
2. It is normal if there is no continuity.

3. Check for continuity between all segments. It is
normal if there is continuity.
Fig 5-12
1. Check for continuity between the yoke and the

field terminal by using a circuit tester. It is normal if
there is continuity.
Fig 5-10
2. Check for continuity between leads by using a

circuit tester. It is normal if there is continuity.
4. Check for short circuit with a glower tester. The

armature is shorted if an iron piece, when placed
on the core while the armature is rotated, is
attracted or vibrates. In that case, replace the
core.
Diesel Engine D427
62
Checking the Brush Holder
Replacement the Brush
Fig 5-13
Fig 5-15
Check for continuity between brush holder (+) line

and brush holder frame with a circuit tester. It is
normal if there is no continuity.
Checking for Brush Wear
Fig 5-16
1. Pull out the brush and brush lead wire from the
brush holder.
2. Remove the brush from the brush lead wire by
crushing the brush.
Fig 5-14
3. Replace a new brush in the brush lead wire. Clean

the brush lead wire. Fix the brush lead by inserting
the lead through the small tapered hole on the
brush.
Check the brush for any damage or wear.

Wear limit : 14 mm (5.51 in)
4. Solder the brush brush lead wire together. Use a

soldering iron of more than 200W.
Diesel Engine D427
63
Checking the Magnetic Switch
Return Test
Attraction Test
Fig 5-19
Fig 5-17
1. Disconnect the lead wire between the terminal and

the starter.
1. Disconnect the lead wire between terminal M and

starter terminal.
2. Connect battery power to terminal M of magnetic

switch and its body.
2. It is normal if the plunger is pulled in and the

pinion jumps out when power is supplied to the
magnetic switch S and the terminal M.
3. Pull and release the pinion. It is normal if the

pinion returns quickly to its original position ; but, if
it does not return, replace the magnetic switch.
CAUTION : Do not supply power for more than 10

seconds.
Pinion Jumping-out Condition
Attraction-holding Test
Fig 5-20
Fig 5-18
1. Disconnect the wire from the terminal M.
1. Disconnect the lead wire between the terminal M

and starter.
2. The pinion jumps out when battery power is

supplied to terminal S and to starer body. Measure
the clearance between the pinion and stopper.
2. Supply battery power to S terminal of magnetic

switch and switch body, and then pull the pinion by
hand.
Standard Pinion clearance :

0 ~ 2.0mm (0 ~ 0.078 in)
3. It is normal if the pinion does not return to its

original position when the pulled-out pinion is
released.
Diesel Engine D427
CAUTION : Do not supply power to starter for

more than 20 seconds.
64
Alternator
Circuit Diagram
Inspection of Charging System
Fig 5-21
Fig 5-23
Charging System Cautions
1. Make current and voltage connections as shown in

the figure.
2. Turn the ignition switch OFF.
1. Be sure battery connections are not reversed,

because this will damage the rectifier.
3. Read the voltage between the L terminal and

ground. The alternator is bad if the reading is not 0
V.
2. Do not use high-voltage testers, such as a

Megger, because they will damage the rectifier.
4. Turn the ignition switch ON and read the voltmeter.

If the reading is 0 V, there is a malfunction of the
alternator or wiring.
3. Remember that battery voltage is always applied

to the alternators B terminal.
4. Do not ground the L terminal while the engine is
running.
5. Do not start the engine while the coupler is
disconnected from the L and R terminals.
Diesel Engine D427
65
Checking No-Load Adjustment

Voltage
Checking Output
Fig 5-25
Fig 5-24
1. Disconnect the negative battery cable.

1. Check to be sure that the battery is fully charged.
2. Connect an ammeter and a voltmeter as shown in

the figure.
2. Connect an ammeter and a voltmeter as shown in

the figure. Be sure that the voltmeter reading is 0 V.
3. Connect the negative battery cable.
3. Turn the ignition key to ON, and then check to be

sure that the voltmeter reading is significantly
lower than the battery voltage(1 ~ 3V). If the
voltmeter reading is the same as the battery
voltage, there may be a malfunction in the
alternator.
4. Start the engine.

5. Apply a increase the engine speed. and read the
output current. If the voltage is higher than the
battery voltage and there is an output current,
there is no problem.
4. Short circuit the terminals of the ammeter, and

then start the engine. After starting, discontinue
the short circuiting.
Removal
NOTE : Be careful, when starting the motor, that the

current of the starter doesnt flow to the ammeter.
5. Under no-load conditions, increase the alternator
speed to 5,000 rpm (engine speed of 2,000 ~
2,500 rpm).
6. Read the indication shown by the voltmeter and
the ammeter.
Ammeter : 5A or less
Vlotemter (adjustment voltage) :
14.7 L 0.3 V (at 20C (68F))
Fig 5-26
1. Lift the seat cushion and fasten is with the strap.

2. Remove the drivers seat cushion.
3. Disconnect the negative battery cable.
4. Remove the drive belt.
5. Disconnect the wire from the B terminal of the
alternator and coupler from the L and R terminals,
and disconnect the wire harness from the clip.
6. Disconnect the vacuum hose and oil hose.
Diesel Engine D427
66
Fornt Bracket and Rotor
Installation
Installation is the reverse order of removal. Note the
following points.
Fig 5-30
Fit a flat-tipped - screwdriver between the front

bracket and the stator core, and than separate the
stator and rotor by tapping the screwdriver with a
nylon hammer.
Fig 5-27
1. Install the drive belt so that the V fits into the

grooves of each pulley.
CAUTION : Be careful not to force the screwdriver

too far in, because the coil may become scratched.
2. Adjust the drive belt tension.
LOCK NUT

Disassemble in numbered order shown in the figure.
Assembly is the reverse order of disassembly.
Fig 5-31
Fig 5-32
Secure the rotor in a vise, and loosen the pulley nut.
Fig 5-28
(1) Front bracket. (2) Fan and pulley. (3) Rotor.
(4) Rear bracket. (5) Stator coil. (6) Brush holder.
(7) Rectifier.
Diesel Engine D427
67
Stator
Brushes
Fig 5-33
Fig 5-35
Use a soldering iron to disconnect the stator lead

wiring.
CAUTION : Do the disconnecting quickly, using the
soldering iron no more than about 5 seconds,
because the rectifier may become damaged if the
inside is overheated.
Brush Holder and ic Regulator Assembly

Fig 5-36
When the rotor is to be attached to the rear bracket,

insert a wire through the hole in the rear bracket so
that the brushes are at the specified position
Seal Washers
Fig 5-34
Use a soldering iron to disconnect the brush holder

and IC regulator assembly from the rectifier.
Fig 5-37
Insert a seal washer at each end of the front bracket.
Diesel Engine D427
68
Inspection
Rotor
Fig 5-38
Fig 5-40
Inspect the following parts, and repair or replace if a

problem is found.
1. Use a circuit tester to check for continuity between

the core and each slip ring.
No-continuity is the normal condition.
Stator
the core and each lead wire. No continuity is the
normal condition.
Fig 5-41
2. Use an ohmmeter to check the resistance between

each slip ring. Resistnace : 3 ~ 4
Fig 5-39

lead wires. Continuity is normal condition.
Diesel Engine D427
69
Rectifiers
Bearings
Fig 5-42
Fig 5-44
Use a continuity tester to check the continuity of each

rectifier. There should be high resistance in one
direction and low resistance in the other direction.
There is a short-circuit if the resistance is low in both
directions, and there is a broken wire if the resistance
is high in both directions. In either instance, replace
the rectifier.
Check the front and rear bearings for improper

rotation and/or abnormal noise. Replace if an
abnormal condition is discovered.
Glow Plugs
Brushes and Spring
Checking Open Circuit of Glow

Plugs
Fig 5-43
Fig 5-45
Check the continuity between the positive terminal of

the glow plug and cylinder head block with a circuit
tester. If there is no continuity, replace the glow plug.
1. Check the force of the brush spring. Measure the

force of the brush spring by using a spring
pressure gauge, and push the brush into the brush
holder until the tip projects 2mm (0.079 in).
Limit : Less than 210 g (7.4 oz)
2. Check for burnt or worn brushes.
Limit : 6.5 mm (0.256 in)
Diesel Engine D427
70
Fig 5-46
Remove in the following order :

1. Glow plug connector attaching nut. Use a suitable
wrench.
2. Glow plug connector
3. Glow plug
NOTE : Turn the glow plug counterclockwise and
remove it.
To install the glow plug, reverse order of removing.
Diesel Engine D427
71
Technical Data
Engine
Item
Type
Diesel, four-cycle
Number and arrangement of cylinders
Four cylinders, in-line
Type of combustion chamber
Swirl floor type

mm B mm(in*in)
Bore and Stroke

Total piston displacement
cc
Compression ratio
92.0 B 101.6 (3.62 B 4.00)

2701
21.5 : 1
Valve system
Over head valve(0HV)
Valve timing
Intake valve
Exhaust valve
Open(BTDC)
14
Closes(ABDC)
44
Open(BBDC)
48
Closes(ATDC)
10
Firing order
1-3-4-2
Idling speed
1075 ~ 1125
Cylinder head
Valve clearance(cold)
mm(in)
Intake
0.30(0.012)
Exhaust
0.30(0.012)
Cylinder head distortion limit
mm(in)
0.10(0.0040)
Valve seat
Seat sinking
mm(in)
Intake
(Length L)
Exhaust
Seat angle
Seat contact width
Valve stem
mm(in)
mm(in)
Intake
standard
48.05(1.892)
Limit
49.05(1.931)
Standard
48.05(1.892)
Limit
49.05(1.931)
Intake
45
Exhaust
30
Intake
2.0(0.079)
Exhaust
20(0.079)
Standard
8.995 ~ 8.989(0.3526 ~ 0.3535)
Limit
Exhaust
8.904(0.3506)
Standard
0.038 ~ 0.085(0.0015 ~ 0.0033)
Limit
Valve stem to guide
clearance
Intake
mm(in)
0.127(0.0050)
Standard
0.038 ~ 0.085(0.0015 ~ 0.0033)
Limit
Exhaust
0.127(0.0050)
Standard
0.058 ~ 0.105(0.0023 ~ 0.0041)
Limit
Diesel Engine D427
0.127(0.0050)
72
Technical Data
Tappet
Standard outer diameter
mm(in)
14.218 ~ 14.223(0.5598 ~ 0.5600)
Standard tappet hole diameter
mm(in)
14.288 ~ 14.319(0.5625 ~ 0.5637)
Clearance between tappet
mm(in)
hole and outer
Standard
0.055 ~ 0.101(0.0022 ~0.0040)
Limit
0.10(0.0040)
Camshaft
Cam height
mm(in)
Intake
Exhaust
Journal
mm(in)
Standard
42.580(1.6764)
Wear limit
42.478(1.6724)
Standard
42.580(1.6764)
Wear limit
42.478(1.6724)
Elliptical limit
Diameter
0.008(0.0003)
1
51.910 ~ 51.940(2.044 ~ 2.045)
51.660 ~ 51.690(2.034 ~ 2.035)
51.410 ~ 51.440(2.024 ~ 2.025)
51.160 ~ 51.190(2.014 ~ 2.015)
Camshaft deflection limit

Camshaft end play
mm(in)
mm(in)
Standard
0.8(0.00079 ~ 0.000709)
0.02 ~ 0.18(0.00079 ~ 0.000709)
Limit
0.3(0.0118)
Connecting rod and connecting rod bearing

Piston pin to small and bushing
clearance
Standard
mm(in)
Connecting rod side

clearance
0.014 ~ 0.44(0.0006 ~ 0.0017)
Limit
0.05(0.0020)
Standard
mm(in)
0.239 ~ 0.330(0.0094 ~ 0.00130)
Limit
Undersize connecting rod bearing
0.4(0.0157)
mm(in)
0.254(0.010), 0.508(0.020), 0.762(0.030)
Crankshaft and main bearing

Crankshaft deflection limit
Crank pin diameter
mm(in)
mm(in)
Standard
57.112 ~ 57.125(2.2485 ~ 2.2490)
Limit
0.05(0.0020)
Grinding limit
Standard
Main journal diameter
Main journal bearing
mm (in)
mm(in)
oil clearance
65.812~69.825(2.7485~2.7490)
0.008(0.0003)
Grinding limit
69.14(2.7220)
Standard
0.059 ~ 0.090(0.0023 ~ 0.00035)
Limit
0.12(0.0047)
mm(in)
mm(in)
Standard
0.254(0.010), 0.508(0.020), 0.762(0.030)

0.14 ~ 0.39(0.0055 ~ 0.0154)
Limit
Diesel Engine D427
56.35 (2.2185)
Limit
Undersize bearings
Crankshaft end play
0.05(0.002)
0.4(0.0157)
73
Technical Data
Cylinder block, piston and piston ring

Distortion limit
0.10(0.0040)
Cylinder liner inner diameter
mm(in)
A : 92.025 ~ 92.037(3.6230 ~ 3.6235)

B : 92.037 ~ 92.050(3.6235 ~ 3.6240)
Cylinder to cylinder liner clearance limit
mm(in)
0.021 ~ 0.078(0.0008 ~ 0.0031)
Cylinder liner wear limit
mm(in)
0.20(0.0079)
Piston standard outer diameter

(Diameter measured at 90 to pin bore
axis and 19 mm(0.75 in) below the oil
ring groove)
Ring groove width
mm(in)
Piston ring thickness
mm(in)
Clearance between piston
mm(in)
ring and ring groove
mm(in)
Top
2.433 ~ 2.453(0.0958 ~ 0.0966)
Second
2.423 ~ 2.443(0.0954 ~ 0.0962)
Oil
4.793 ~ 4.813(0.1887 ~ 0.1895)
Top
2.363 ~ 2.383(0.0930 ~ 0.0938)
Second
2.363 ~ 2.383(0.0930 ~ 0.0938)
Oil
3.97 ~ 3.99(0.1563 ~ 0.1571)
Top
0.05 ~ 0.09(0.0020 ~ 0.0035)
Second
0.04 ~ 0.08(0.0016 ~ 0.0032)
Oil
0.830 ~ 1.043(0.0316 ~ 0.0411)
Wear limit
Piston ring end gap
mm(in)
A : 91.967 ~ 91.980(3.6207 ~ 3.6213)

B: 91.980 ~ 91.993(3.6213 ~ 3.6218)
0.3(0.0118)
Top
0.35 ~ 0.55(0.0138 ~ 0.0217)
Second
0.35~ 0.55(0.0138 ~ 0.0217)
Oil
O.35 ~ 0.55(0.0138 ~ 0.0217)
Wear limit
0.3(0.0118)
Piston pin diameter
mm(in)
Tightening torque
m kg(ft-lb)
Cylinder head(cold engine)

Manifold
31.744 ~ 31.749(1.2498 ~ 1.2500)
11.0 ~ 11.7(80 ~ 85)

Intake
1.6 ~ 2.4(12 ~ 17)
Exhaust
2.7 ~ 3.3(20 ~ 24)
Crankshaft pulley
3.5 ~ 4.0(25 ~ 29)
Camshaft thrust plate
1.6 ~ 2.4(12 ~ 17)
Connecting rod bearing caps
7.6 ~ 8.3(55 ~22)
Cooling fan
1.6 ~ 2.4(12 ~ 17)
Injection pipe
2.5 ~ 3.0(18 ~ 22)
Oil pan
1.6 ~ 2.3(12 ~ 17)
Main bearing cap
11.0 ~ 11.7(80 ~ 85)
Idle gear
2.3 ~ 3.2(17 ~ 23)
Rear oil seal
1.5 ~ 2.0(11 ~ 14)
Water pump
1.6 ~ 2.3(12 ~ 17)
Camshaft gear
6.2 ~ 7.0 (45 ~ 51)
lnjection pump gear
4.0 ~ 7.0(29 ~ 51)
Diesel Engine D427
74
Technical Data
Lubrication System
Item
Specification
Lubricating method
Force-fed type
Oil Pump
Type
Trochoid type
kg/cm2(lb/in2)
Oil pressure
Outer rotor and body
mm(in)
clearance
Standard
0.14 ~ 0.25(0.0055 ~ 0.0098)
Limit
Pump shaft and body
mm(in)
clearance
3.8(54) or more
0.3(0.0118)
Standard
0.06 ~ 0.15(0.0024 ~ 0.0059)
Limit
0.1(0.0039)
Tightening torque
mkg (ft-lb)
Oil filter
By hand + 1/2 turn
Oil pan
1.6 ~ 2.3(12 ~ 17)
Oil pipe
0.8 ~ 1.2(6 ~ 9)
Oil pressure switch
1.2 ~ 1.8 (9 ~ 13)
Cooling System
Item
Specification
Fan belt tension
New belt
10 ~ 12(0.39 ~ 0.47)
(10kg force
Used belt
13 ~ 16(0.51 ~ 0.63)
mm(in)
Fan
Type
Blower
Number of blades
Outer diameter
6
mm(in)
430(16.93)
Item
Thermostat
Specification
Opening temp C(F)
82 L 1.5(179.6 L 34.7)
Full-open temp C(F)
95(203)
Full-open lift mm(in)
8.0(0.31)
Water pump
Type
Centrifugal, timing belt driven
Radiator
Type
Corrugated
1.0 L 0.15(14.2 L 2.1)
Cap valve opening

Pressure kg/cm2(lb/in2)
Diesel Engine D427
75
Technical Data
Fuel System
Item
Specification
1100 L 25
Idle speed rpm

Injection timing
ATDC 2
2
Injection pressure
kg/cm (lb/in )
Tightening torque
135 ~ 140(1920 ~ 1991)

mkg (ft-lb)
Injection pump gear
4.0 ~ 7.0(29 ~ 51)
Injection nozzle holder
6.0 ~ 8.0(43 ~ 58)
Injection pipe
2.5 ~ 3.0(18 ~ 22)
Engine electrical system

Item
Specification
Charging system
Alternator
Type
Voltage capacity
Alternating
V-A
Regulated voltage
12 - 60
14.4 L 0.3
Starting system
Starting motor
Type
Electromagnetic push-in type
Voltage
12
kW
2.5
Voltage
11
Current
200 or less
Speed
rpm
3000 or more
Output
Free running test
Tightening torque
mkg (ft-lb)
Starting motor
8.9 ~ 12.0(64 ~ 87)
Alternator
1.8 ~ 2.7(13 ~ 20)

Tightening torque
mkg (ft-lb)
Flywheel Housing
3.3 ~ 4.8(23 ~ 34)
Flywheel
Diesel Engine D427
13.1 ~ 13.8(94 ~ 99)
76
Technical Data

D 427 Diezel Engine

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D 427 Diezel Engine

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SB4034E00

Important Safety Information

2.1. General Information

Diesel Engine D427

Engine Electrical System

Technical Data ..............................................72

Diesel Engine D427

Number and arrangement of cylinders

Four cylinders, in-line

Type of combustion chamber

Swirl floor type

Over head valve(O.H.V)

Bore and stroke

Diesel Engine D427

92.0 X 101.6(3.62 X 4.00)

Malfunction of engine-related components

Malfunction of engine related components

Malfunction of engine-related components

Diesel Engine D427

Diesel Engine D427

Adjustment of Cylinder Head

Adjustment of Cylinder Head

1. Remove the cylinder head cover.

2. With the No. 1 cylinder piston at TDC, check and

1. Remove the cylinder head cover.

Intake side : No.1, No.2

3. Tighten head bolts to the specified torque, in the

3. Set the No.1 cylinder to compression TDC by

Tightening torque(under cold engine condition) :

Intake side : No.3, No.4

Diesel Engine D427

3. Set measuring instrument to injection pump. Make

4. With the flywheel ring gear in proximity to BTDC

5. When it is confirmed that the needle of dial guage

1. Remove all injection pipes.

2. Remove the head bolt and gasket from the

Cam lift for optimal injection timing : 1.00 mm (0.039 in)

Injection timing is too early when cam lift value is

1. Warm up the engine thoroughly.

1. If injection timing is not right, then turn the injection

3. Install the adapter set and use a pressure gauge

2. Install the bolts and gasket after adjusting.

3. Install the injection pipes.

Diesel Engine D427

Disassembly and Assembly

Diesel Engine D427

Diesel Engine D427

Diesel Engine D427

Diesel Engine D427

Diesel Engine D427

11. Disassemble the pulley lock bolts and crankshaft

14. Remove the valve guide, pushing it towards

15. Assemble the valve guide in the following order.

(1) Set valve guide on the opposite side of the

13. Remove the taper sleeve after compressing the

Diesel Engine D427

16. Remove the piston pin by using the piston pin

19. Assemble the piston rings and oil rings onto

17. Assemble the piston and connecting rod, after

20. Install the piston into cylinder block by using the

18. Assemble the piston rings after checking that the

Diesel Engine D427

21. Adjust valve clearance after assembling. Oil pan

24. Remove the injection pump gear by using the