YANMAR SERVICE MANUAL DIESEL OUTBOARD MOTORFOREWORD ‘This service manual outines procedures for servicing and maintaining YANMAR O27A/ D96A DIESEL OUTBOARD MOTOR to obtain maximum iHe and performance, it explains about the structure, performance, disassembly and reassembly procedures, important inspection points, servicing instructions and the wear limit of parts. For full Lundorstanding ofthis manual, also refer tothe Operation Manual and Parts Catalog. Besides ‘elerance use at your service shop, this manual can also be used as a tex! for your service ‘engineers. Aull understanding of the content of this manual leads to accurate and efficent services. Good servicing guarantees the machine's performance and prevents troubles. Please note that there may be changes in the structure explanations of maintenance instructions resulting from future improvements in quaity and performancs. Ityou have any ‘questions, please contact us. For accurate and efficient work, the following preparations are necessary: 1. Check the customer's service chart 1) When was the last service? 2) How many months or hours has the machine been used since the last service? '3) What was the trouble and what parts were replaced in the last service? 14) What parts must be replaced in the present service? 2. Preparation of parts ‘Check the inventory of parts that are necessary for servicing, 2. Preparation of report forms Inspection and service check sheets, parts measurement record forms and operation test record forms. 4, Prepare the servicing tools, measuring instruments and containars.ete. This product has boon developed, designed and manufactured in accordance with the Standards for Quality System of ISO 9001 (Intemational Organ- zaion for Standardization) under te folowing authorizd insiations: JM (Japan Machinery and Metals Inspecton) Insitute, BS! (Brish Standards Instision) and EQNET (The European Network for Quality System Assessment and Corticaton) Contes under the folowing standards: 1SO 9001 Certified §SO 9001 - 1987 / BS 5750 : Part 1: 1987 / EN 20001 - 1987 / IS Z9901 - 1991 Printed in Japan "ADASDS5 JOSwoo. D27A & D3GA CHAPTER 1 GENERAL 1. Speeitications ... 2, Exterior View 7 . 8. Cross-sectional View . 110 CHAPTER 2 DISASSEMBLY AND REASSEMBLY 1. Proparations Before Disassombly and Reassembly 2. Tools, Measuring Instuments and Serco Equipment «ono 22 3. Exploded View of Parts 242 4, Rleassembly Procedures... eons BAA 5. Reassombly Procedures for Drive Unit 229 CHAPTER 3 INSPECTION AND SERVICE PROCEDURES FOR ENGINE PARTS Inspection and Service Procedures for Engine Parts 7 Cylinder Block Rtn end Corvctg Fos - Crankshaft Camshat nen Cylinder Head : : Valve Arm Case .... on 19 Intake/Eshaust Valve Arm and Unk Injector. a4 Thermostat soe BAT Unit Injector seornennene GAB Governer.. 4 1 CHAPTER 4 REASSEMBLING AND SERVICING OF DRIVE UNIT 1. SwivalSteering Bracket 2. Clamp Bracket 38, Upper C80 nn 4. Botiom Cowing and Fiting Pans 5. Lowor Gear Case .. 49 6. Cocing Water Pump and Cooling Water Piping =... 415 7. Steering Handle... 416 8. Hydraulic Cylinder... van 47 9. Electric Hydraue Titing 418 10. Senncing Upper Case win " Seog BrackOt wenn sn Printed in Japan "AOASO55-JCO3 ‘CHAPTER 5 PIPING DIAGRAM 1. Piping Diagram a4 (CHAPTER 6 ELECTRIC EQUIPMENT 1. Generator. it tear eee 2, Starting Motor (Reduction Gear) 62 3. Waming Device ... : 64 4. Wiring Diagram CHAPTER 7 SERVICE STANDARD 1. Service Standard Table (Engine) .... 74 2, Sarviee Standard Table (Orive Unit) 73a CHAPTER 8 MAIN BOLT TIGHTENING TORQUE 1, Main Bolt Tightening Torque a CHAPTER @ BACKLASH ADJUSTMENT 4, Backlash Adjustment 7 9a (CHAPTER 10 PERIODICAL INSPECTION 1. Periodical Inspection Table 40-4 CHAPTER 11 OPTION 1. Diesel Outboard Propellor Guard Holes.CHAPTER 1 GENERAL 1. SpecticioN os nnninsnnnnsnsnnnnnienmnnsne VA 2. Exteror View . eenree 3. Cross-sectional VIEW sewn eg Printed in Japan ‘AOABOSS JCO3Chapter I General 1, Specifications $$ ___________SMD27A & D36A 1. Specifications 1-1 D27A and D36A series a T aA aba nee xe_[ xep | ve [ ¥ | xe] xer | ve | ver se 128 (When folding 1167 (When folding eee om 730 _[thahancte 730) ae the handle 789), Dicreil wae amy Ea = a a Te wo | — | wae | tar | te | — | — | te | tes | | tags | 1480 eee ee Overait height (mm) GE | | A | lee Pere eceeee ere suc | mo | — | 169 | 1522 —|—-|[=— L 60 ae ae |e § | Transom fengih (mm) Gr | ar eee ee eee ee | SUL 75) — | — See EE eee eee 3 L a | we | o | x | 16 | 1 {a0 Seen toi} Le 2 | ms | | 93 | waa ma Pen Welge 149)! op | soe | oo | oo | ne |e v2 : su. | 97 | 105 | 8 | 95 '— | — Tk ayater ~—Fitanval Hyaraulic Menusi | Menual | Manuel Hydreulid Manual Hydraulic Sterting system Exectric | Electric | Elecirio | Roooil | Eleawic | Elestri | Electric | Electric | i Remoie | Remote Ber | Ber | Remote | Remote| Ber | Bar | eeeering sie contral_| cortral_ handle | handle | control control | hand | handle waKW 7 waKW 7 Max. Output Bann / strom | ESO attra Type 4 oyela water cooled, Vertical Crankshatt Diesel Engine tao! cylinders 3 Bore » Stroxe (mil 70x70 T Bx Displacement a 808 i Tr08 Combustion system Direct injestion by M~iype unit injeetor Brake moon elloctive pressure TWOP (.18het/ot) ‘OGM Pa (6.08het a) ‘Mean piston speed 1.8/5 | Mox. combustion pressure Zeampression ratio enna eat ete Pion eee 6.9020.0/0.20 0.552 0.8/0.200 Fuel injection tiring Few bT0e Fic BTC YDLLA-P-type hole nozzie YDLLA-P-type hole nozzle g | Fuel injection nozzle ee Tato _E | Fuel injection valve opening pressure 19,610.49 MP0(200%5 helen) Firing order 240% 240% 5 240°. Direction of evolution Clockwise (viewed from flywheel side) Power teke-oft direction Counter = flywheel si Driving system of intake eae 1 exhaust valve and fuel pump eee eee Intake systern Intake inertia low pipe Exhaust system Cooling water mixing end underwater exheust system Lubricating system Forced lubrication by trochoid pump ‘Lube oi! sump] Full smount rae 308 cepacity | Efetive amount ioe 13e Type of lube oil ‘API service grade CD class SAE T6W_40 Printed in Japan ‘AOASOSS-JCO3 aChapter 1 General 4, Specifications Sind & 364 Daa DaeA ae XE XEP, YE Y XE XEP YE YEP Cooling system Direct seawater cooling By rubber impeler pump Fuel fed system Pressure toading by trochoid pump 2 [Governor tye Mchanical floating wr vb8 E [starter copacity wav — 12k = av - ake ‘Generator type / cops ‘Dynamo Rouse intlywheat/ 2V~ 108 Bostory conecity 1av-1008 = 12V=100AH or more $l Fuel tenk twpe/capacity Portable / 288 E Feturned to tank when overtiowing, wih rimery vale, [pg renee with onetoueh joint onthe fel terk side Steering angle Hf Max. 40 degrees right ~to~ left econtrar | BE P8MSIEGE | Berice contrat | Bar handle grip Sores coolest endansin_ Ramstecontal | otungsatem BAMBEENH! cing aya i _ 85 ° 3 ‘stops Power tilt] 4 sieps steps Power ti] Ssteos [Power ti > Tilting step and angle T=22° | Arbitrery)| ra 8°=24° |(Arbitrary)| 8°-24" |(Arbitrary)| 5 | Max. tilting up angle 78 78° 6B 78 16° 76 z - | & | Anate when running in jp) bess thon) 32° (When viting | ayec,,y [ese then) aye; Lose ther| sea ana '2000 rpm| angle is 7° ) oe {2000 ram} 22°") |000 rpm Hull mounting Bolted to transom plate Clutoh type end eperation Dog type clutch lever operation +) Reduction geer type Bevel geor 2 & Reduction ratio Ea 1 23 (forward / reverse) eee ls 8: Lubrication system ‘Oi bath Lube oi capacity fen Type of ei Gear oil API serve grede SAE BOW 20 Driving (damping) system Spline and rubber press Fitting type [Direction of rotation Clockwise (viewed from propeller sige) = | Mex. rom (forward / reverse) 2438 ram / 1356—1625rpm, & 006.7 x 208 ~ 2002.1 x 228.6— Number of bladet~ciemater > pie 3-200.7 330 $202.1 381 (14 08) (10 types) *1) Dry weight of outboard motor i Proved n Japan ‘AOASOSS-JO03Chapter 1 General Bi erserior Vie CEeeee eer eee cence eee eee eeee eee eee cecee eee eee eee eee ee eee ee guna de DSO 2. Exterior View 2-4 D27A series (1) D27ax ro TOBET | Ties Bee ar | : ao rt \ ee \ a Be i. § NESE 4 y ~ ie up oa Sed / ye” ZUNE — Me Parsea i Japan ‘ADABOES.JCO3 7Chapter 1 General fe Eivterior View eee eee eee eee ee SanZ7A a DS0Al (2) D27AXEP cryooer Cesr (TOBE Liaise nOEWaT : Cees (in) se9 (ang )sez at 790 Printed in Japan 7 ‘ROASOSSJCOSChapter I General 2. Exterior View IMID27A & D364 (9) O27AYE CHvETT cz CHVeaET | A f Cie BEE sa — TOSS ino ran FOBNVAT (e29 * | i (19) $09 au Z \, EMT yf ins ysgu \ THetr 299 Painted in Japan ‘AOASDS5 C03. 15Chapter 1 General 2. Exterior View sty 274 & 364 (4 De7AY Cvedt EE Tater i " Teer, bez 5oF é A eee eae iat rine in Japan 16 ‘AOASOSS-JCO3Chapter 1 General 2. Exterior View SMID27A & D36A TyeeeF 2-2 DS6A series (1) 36Ax, Printed in Japan ‘ROASOSS. COSChapter 1 General 2. Exterior View (2) D36AXEP, SMID27A & D36A TTBEST Printed in ‘AQASOSS.1CO3)Chapter I General 2. Exterior View SMID27A & D36A (3) O36aY CUBEDT rind in Japan i "AOABO55-JC03;MID27A & D36A 3. Cross-sectional View Chapter 1 General 3. Cross-sectional View (1) D27AX rite in Japan ‘ROASOSS-100SChapter 1 General 3. Cross-sectional View SMID27A & D36A (2) D27AY Printed io Japan 1 "ADASO55-JCO3SMID27A & D36A 3. Cross-sectional View (3) D36AX Chapter 1 General Painted in Japan 5C03 ‘AOASOS:CHAPTER 2 DISASSEMBLY AND REASSEMBLY 1. Proparations Bofore Disassembly and assembly 24 2. Tools, Measuring instruments and Service EQUIPMER vec rvnnn rennin 22 2 Exploded View o! Pants ane 4, Reassombly Procedures... i se BNE §. Reassembly Procedures for Drive Unit 229 Printed In Japan ‘ROASOSSICOSChapter 2 Disassembly and Reassembly 1. Preparations Before Disassembly and Reassembly M/D27A & D36A 1. Preparations Before Disassembly and Reassembly 1-1 Visual symbols for disassembly and reassembly Visual Mark Description | Visual Mark { Description aS tion A Caution Safety aan rT 1 > | Messure | clean | | a Git suppl | 3 | z 7" ‘Use torque wrench 4.2 Disassembly (1) Prepare tools, measuring instruments ard record sheets {2) Prepare the cleaning machine and clearing vessel (3) Propare a tomporary stocking area and container for removed pars. (4) Orain cooing wator and lube oil trom the engine. (6) Put the disassembled parts in order. (6) The materials and dimensions of bolts arc cuts citer from each other. To prevent insertion of wrong bolts or ruts, thread them loosely in their onginal position after disassembly. (7) Determine the cause of trouble accurately before cis- assembly, and do not remove or disassemble unneces- sary parts. Printed in Japan "AOASOSS JOOS 2a "1 Applicable iquid packing: THREE BOND 12078 THREE BOND 1215 for drive unit "2 Numeric characters show width across fats, 1-3. Reassembly (1) Completely clean the parts, and then check their con ditions betore reassembly. (2) Apply new engine oil to sliding parts or moving parts belore reassembly. (3) Replace all gaskets and O-rings with new ones, (4) Apply the specified liquid packing to the necessary parts 10 prevent wator or ail leakage. (5) Fit each part while checking oll clearance and thrust clearance. (6) For parts having match marks, fit the parts by aligning the match marks. Take care of the combination of the parts with selective engagement (7) Be sure to use specified bolts, nuts and washers. Tighten ‘the main boits and nuts to the specified torque. Take special care when tightening aluminum alloy parts (®) Apply engine oil tothe threads and bearing surfaces ‘of main bolts, and tighten them to the specitied fighten- ing torque,Chapter 2 Disassembly and Reassembly 2. Tools, Measuring Instruments and Service Equipment SMID27A & D36A 2. Tools, Measuring Instruments and Service Equipment Although the tools supplied by YANMAR allow you to dis: ascomble of reassemble the main part of an engine, it recommended to. use the following’ tools and parts. for efecive and accurate working and correct éagrases 2-4, Special tools for disassembly and reassembly (engine side) code te | Na] Name ] Description/Usage Drawing 1/| Nozzle opening valve | 12027-93010 prosnure satiny hale | | a) | | | | [2 | injector holder —=~SC=*sY*«1 20270-93020 | 3 | Five! removing oor”) 2070-860 yar as ae | Mea ere tees | parte ome | We apes Tract bax bien “AOAGO55-JCO3Chapter 2 Disassembly and Reassembly 2. Tools, Measuring Instruments and Service Equipment MIDITA & D36A Ko Name Code Na Deseription/Usage Drawing 4! Flywheel fixing le 120270-89870 26106-080162 MBX 16 2pes. /¢ [5 Valve ster seat press. |120270-99820 fitting too! | “| Se Pressctitting | 4 Nal | LJ stem seat Valve guice | Unit injector removing |120270~99840 | | 7 | Clearance jig (D27A) Clearance jig for stator end dynamo| Each gio for exclusive 20270-00000 |wheet jse (Osa) | Yan2ebeca00 SS, 8 | Valve guide removing too! |120270-99770 | (027A) 7 | 20270-99790 = = | (036A) i | 20380-99790 i n 4 From inside of eylinder to valve arm case Printed in Japan ‘AOAOSS.JCO3 28Chapter 2 Disassembly and Reassembly 2. Tools, Measuring Instruments and Service Equipment ‘MID27A & D36A Na Name | code Mm Description/Usage Drawing 9 | Vaive guide press-fitting «0120270 1 | tool and hand reamer “99770 ' ® oy | (027A) L | 20270 ft ~99700 ‘oD |(oaeay 3 1120380 ~29700 | @r0270 eft \ 99760 Positioning of fixing guide which ona | | fixes the position of velve guide et aati the start of press: eae : 10] Valve seat removing tool 1¥20380-99500 (Weld-removing piece) ® (pray 120270-99620 i (036A) Hl 20380-99620 (D27A) 20270-99630 1 (036A) 20380-90690 20380-99610 (027A) 120270-99460 (026A) 20380-99460 (027A) 12027099460 (036A) (Seat removing rod@, (2) Weid-and.ramove piece Note:1) Install an exhaust valve (20880-11111 ater at * part ‘aveapee 20380-99460 | Note:t) There rust ba 90 return. (a re esate Be aire Vara S (Teflon seat and seat removing tool) remove piace ‘Stponiet "Oe Tellon seat @ Thm dimension of D and are described nthe faloning a Rae RFT GON Tan T—[ Waairersepaai [RST [poor Seip are ser] Sa ~ ® 32.520. | For DBA Soe] e paseo ‘11) Valve seat press-fitting tool (D27A) (D36A) Use liquid nitrogen (Cold fitting) 120270 120270 1. 120270 ~ 99640 (027A) ~99650(S) ~99650(S) veoaao~ea640 (Oa) —_|120270 1202t0 Each oo! is for oxclusive | —60660(E) | —00860(E) use. aren” (araazr 7 =99670(s) |” -995708(S) : | 120270 120380 ! ~99680(E) -99680(E) : | = Prien Japan ‘AOASOSS-JCO3Chapter 2 Disassembly and Reassembly 2. Tools, Measuring Instruments and Service Equipment ;MID27A & D36A No Name tool 13| Fusl injection adjusting jig Code Ne 12, Valve clearance adjusting |120270~- 99660 120270 - 99800 14! Adjuster jig 120270 99881 Description/Usage Drawing Clearance gaugold 2mm, Fiking jig 15] Grease pump 196311 4 92460 = | 2 SF aN jor 16] Micrometer 0-25mm 25-60mm 50-76mm 17| Cylinder gauge #7 10- 1mm 18- 35mm 35- 60mm 50-100mm 2.2. Spocial tools for disassembly and reasembly of lower unit Ne Name Code Na Description/Usage Drawing 1 | Backlash tool 196640-92910 (Refer P9-1) ‘oot | \ 19630-92940 Indicator Clesrance y - 052002 : | Toot rites in Japan “AASOS5.JCO3 28Chapter 2 Disassembly and Reassembly 2. Tools, Measuring Instruments and Service Equipment SMID27A & D36A Name Codes Description/Usage | Drawing Inctcator plate 196630 - 92060 Na 2 Dial gauge | | 3 Forwarding gear positioning |196640~ 92920 tool 198640 — 92670 {95810-92170 | | (Reter te P90 25636~100002 | 3 | (2) | | exuane ' (19x20) | | & 4 | Reversing gear positioning [79864092020 tool (26736-60002 | 6640-22180 |22197— t6oo00 Cc) (Refer to P.9-2) |22137 - 240000 26746-4002 | COS) | | | wig) cats | | ieee | 5 | Bearing removing tool 196630 — 92510 Ht tos640~02111 96630 97690 196630 22620 26737 ~ 140002 | | 198640 ~ 92681 | 196620 22640 | | mutT 200%60 22187 ~ 140000 | mia =o Qe 6 | Bearing press-fitting tool |@196640~92760 119664092760 | (ozay (D27A) |@ 96640-92771 | 96630-92121 1324311~000210 | (036A) 19663092800 Spocer 96640-92121 (036A) { (2 196640~92771 | 24311-00210 | | | | nly O77 hi i Uns spacer 7 Printed in Japan ‘AOASOS5-JC03Chapter 2 Disassembly and Reassembly 2. Tools, Measuring Instruments and Service Equipment ely uel Na Name Code Na Description/ Usage Drawing 7 | Neadie bearing disassem- |196040-92600 | bling too! Jotnars are. those | (Oil seat case spacer) —_| used as tho bearing eroxing too! 8| Needle bearing reassem- | 19640-92610 bling tool 96640-92620, 96640-92140 9 Needle bearing disassem- (1196640 bling tool 92560 96640-92160 (2198640 92560 (196640 92570 i 26736-14002 Nut shaft 14 |22t37—s40000 | Plain washer '24311-000210 O-ring 10] Needle bearing reassem- |196630-92680 bling tool Others are those lused as the needle bearing dissssem. bing toot 11{ Oil seal reassembling _|cDt96840-02760 tool (027A) 96640-02760 (2)196630-92781 | (027A) @196640-82790 | {96630-92131 (036A) (036A) (2196640-02781 19684092131 (90640-82760, Printed in Japan a ‘AOASOSSJCO3Chapter 2 Disassembly and Reassembly 2. Tools, Measuring Instruments and Service Equipment SMID2I7A & D364 Na Name Code No Description/Usage Drawing tool, * a 13| Rod cover 19652792900 L400 W38x HT | 3 g az ca ow 14[ Bort pes (Only for D27A | 6x20 | |26716— 100002 M10 | oe “AQASO55-JCO3-Chapter 2 Disassembly and Reassembly 2. Tools, Measuring Instruments and Service Equipment cinta see ha] Name. Code | Deseription/Usage [Drawing 15. Spline sleeve |coz7ay | | S520 cso j |(D36A) | Bo acto | | : Z T8| Formarding gor reovoon 8660 Gave | Binge! ot “eon ave A Tana aise | | | 17] Reversing gear reassem- bling too! set ‘96640-92090, C@| G@ | 3 18| Forwarding/reversing gear|196600~ 92850 | disassembling tool 96640-92860, | 16640-92100 25116~ 081002 —= 2718-2 | | | | | | L | Prrted in Jaoan ‘ADASDS5JCO3 20Chapter 2 Disassembly and Reassembly Tools, Measuring Instruments and Service Equipment SMiDaTA a aed No Name Code Na Description/Usage Drawing 18| Oi! seal reassembling tool |(D27A) | (074) (D196640-92710 196630-92161 (96630-92721 (036A) \@196690-92731 @ @ 1640-92160 (D26a) | (96640-92710 \ |(2)196640-92720 i \()196640-92730 \@r966e0—92750 7 » (Pena) 28. Gauges for servicing Name | code Na. Deseription/Usage Drawing Loading 19664082010 | Testing propeller 2 Stand For display and repair 3. Washing joint 19663092460 | Screwed into the lower case when | washing, The water port is plugged up. 4 | Tachometer set 120270 98260 ing iat ume 4 Nt: Engine rpm igineaneterciuton dtctor | N2: Tachometer reading 121 Extension cable 8 N1=60/971N2(D27A) GGiDigtat techometer M620 (Ono Ni=60/107 "8ke-m Install the tilt tube cap. (Too much tightening damages the| tilt tube cap because it is made of plastic.) 12) Install the power unit to the clamp bracket, (Apply THREE BOND 1215 to the bolts.) Tightening torque] 2legf-m 18) Pass through the clamo bracket | "grommet hole, and fix it with @ grommet. (Use @ rubber grommot out with a scissor) {Cut the rubber grommet and insert it} Printed in Japan bane ‘ADASOS5 COS,Chapter 2 Disassembly and Reassembly 5. Reassembly Procedures for Drive Unit ;MID27A & D36A Na} Item’ Procedure seal tape, (2adapters for the hydraulic cylinder and 2 adapters for the power unit) tight part. \ 16) Install the thrust rod. 14) Install 4 flare adapters attaching @ 15) Install the flare tube, and adjust it so that it does not contact with any Symbol ome] wwe Ih Photo/Diagram (Install the thrust rod)Chapter 2 Disassembly and Reassembly 5, Reassembly Procedures for Drive Unit Na ttem 5 | Bottoms [cowling (Rafer tp 6) 6 Shite bracket (Rete p-7.) = Procedure symbol Photo/Diegram 1) Install the bottom cowling (with a FO connector. a stop wire, a key switeh, a LO warning lamp, @ battery cord, 2 grommot brackets) to the engine mount. Tighten the collar. the grommet and the washer with united bolts. Tightening torque, 0.Bkgf-m Note: ——___—- Insert washers if the bolts are tightened on aluminum body. 2) Install the holder A to the bottom cowling. (harness) (The holder A fixing screw is tapping! screw, and the washer is made of plastic.) 1) Install the shift rod to the detent with a shift rod pin, and fix it with a washer and a Split pin, 2) Install the detent and the shift shat, and fix it with a spiral roller pin 3) Install the safety lover. and fix it on the shift shaft with a spical roller pin. 4) Install the reverse limit shaft to the reverse lever with @ spiral roller pin. 5) Install the detent spring A end 8 (Install the shift bracket (apy gece tthe detent spring.) | {stop bracket for 027A) assembly) 6) Install the shift bracket (stop bracke! for D27A) assembly to the engine mount 7) tostalt the bottom cowling te the engine mount i ‘As for 027A, oush seal rubber with | a pushing plate. AAS for D36A, tighten the grommet with bolts and nuts. | Ghitt bracket {stop bracket for D27A) assembly) Pntod in Japan ba "ADASOSS JCOB MID27A & D36AChapter 2 Disassembly and Reassembly 5. Reassembly Procedures for Drive Unit SMID27A & D364 me tem | Provedure Symbol Photo/Diagram 7 | Steering | 1) Sandwich the wave washer between | handle,ete | washers, insert a bush and install | , (Reertop4-18]| the steering handle. Max25, MBx65 | (applied with THREE BOND 1215) | Insert the bush in the steering handle, and fix it with the handle support | 2) stall he grommet tothe regulate [Peete aha Sere easorbhy the i | Sonne Song 4) Install the steering brake to the swivel bracket Wave washer | (Install a spring, a rubber and a 7 ) washer with a set bolt.) | | | [8 [sexing 1) Knock 2 knock pins ino to lower ‘ower oor case, and (Apply THREE BOND 1215 to the [oner aear] “pine 2) Fit the extension for the LL and UL models, | (Apply THREE BOND 1216 to the whole installation surface) 3) Insert the cooling water pipe into the { cooling water outlet side of the lower) gear case. Note: ——__________, ‘Attach water seal rubbers on | | the upper and lower side of the cooling water pipe before | | | inserting the pine. ) Insert the water seal rubbor into the! {2276 ( upper case, fix the rubber with the Seal rubber cose, end install the jower gear case Tae aie] Wot) a, [Ss inn 3) Tightening torque| tem shatt [aA [ress0-one ost -Giet ese] — 7 Siew (SUL For D27A only) 5) install the connection on sear] een -i0am | 8) Connect the shift rod and the shift [fier ~~ 07) ro cam using the connector —— —| Set both at the reverse condition, | ete ——_t_— land tighten them with nuts, fit carn [19060-00852 | 19 a Printed in Japan oh "AGASOSS.JCO3Chapter 2 Disassembly and Reassembly 5. Reassembly Procedures for Drive Unit SMID27A & D36A Na} tem Procedure Photo/Diagram | 8 | Brocket | 1) Insert a plate into the pivot shoft. and set the upper and lower bushes. (The lip sides of the upper and lower ush should face the inside.) {nstatl the upper and lower washers | (Apply grease to the washers.) 2) Insert the pivot shaft. | 3) Install the bracket mount to the lower side of the pivot shaft. (Do not forget to install the rubber damper.) Warm the bracket damper before Inserting it. Insert it with a bolt nut, and fix it with a washer and a stop ring. 4) Install the upper case assembly to tho swivel bracket assembly. ——_—-— Tightening torque) 3.8kgf-m | | Attach stopper and a washer (applied with screw lock) to the bolt, and | Ughten it. The lower side should be tightened with a washer and s nut. | ‘The upper side should be tightened with no stopper and screw lock Insert a screwdriver into the rubber |. side to fix the bolt when tightening. 5) Install the bracket handle. (Apply THREE BOND 12078.) 6) Install the fower mount housing, (Apply THREE 80ND 12078.) [coment ratartower sw) 22 {Insert the upper and lower bush) L =» (Insert the pivot shaft) (Install the upper case assembly) Prinied in Japan ‘AOASOSS-JCOBCHAPTER 3 INSPECTION AND SERVICE PROCEDURES FOR ENGINE PARTS id Service Procedures for Printed in Japan ‘AQASOSS JC03Chapter 3 Inspection and Service Procedures for Engine Parts 1. Inspection and Service Procedures for Engine Parts Terr 1. Inspection and Service Procedures for Engine Parts 1-1 Do the following procedures before inspection and ‘service of main parts (1) Clean all parts completely to remove dust, oil, carbon and scala, etc. (2) Blow comprassed air through oll holes to remove deposit ‘and check that there is no clogging. (8) Remove carbon deposited on the cylinder head and the intake/exhaust valve, etc. with care so that the parts will not be damaged. (4) Put in order the parts that have a definite combination to prevent confusion Printod in Japan "AOASOSS-JCO3 1-2 Standard for replacing (repalring) parts ‘Measure each part and check it according to the respective inspection procedures. 'f the part is defective or exceeds the wear limit, replace it, Also replace any part which is expected to exceed the wear limit by the next inspection even if iis within the wear kit ow.Chapter 3 Inspection and Service Procedures for Engine Parts 2. Cylinder Block S027 & DI6A 2. Cylinder block ‘The cylinder block integrates the cylinder head, the cooling water jacket and the crank case. The exhaust manifold is housed inside, and the cylinder liners are cast in the cyl Inder block. 1. Cautions when reassembling and servicing (1) Provide high pressure steam cleaning to the inside of the cylindar block, the cylinder head and each oil hoie. (2) Knock 2 knock bushes into the top of the cylinder head, (3) Replace the old anti-corrosive zinc. 2. Cylinder finer ‘The cylinder liners are cast in the cylinder block. They employ the girect seawater cooling system (1) Cautions when reassembling and servicing 1) Check the inside surface of the cylinder liner, and measure the inside diameter of the bner. Repair the part according to reboring (oversize of 0.25) it it exceeds the size limit (mm) T Siendare 1 Wear nit L870 40.090 (982) 10.020 Lins inside y) 279 #00 | M10 samen Sse | GLB) for Da6A (Cylinder block) i Printed in Japan ‘AOAS055-JC03Chapter 3 Inspection and Service Procedures for Engine Parts 2. Cylinder Block 3. Main bearing and main bearing case + The main bearing is @ 4-point bearing aluminum metal ‘The thrust bearing consists ol circular at upperside and. ful-cireular at towerside. ‘= The main bearing case, which comes in a monoblock is connected and tightened to the cylinder block at the center of the crankshaft. The oil cooler is installed in place of the bottom lid. (Oil cooler is for D36 only) (1) Cautions when reassembling and servicing 1) Install the main bearing, and tighten the main bear- ing case to the specified tightening torque. Measure the inside diameter of the main bearing, and replace it if it exceeds the wear limit Da7A @e® (mm “| standard | Wear limit Main bearing] 4 gyi 028 ‘0 ide dia. | *M0+0.010 ad Cap bolt (M10) | Head, wioth (14) out 5 tightening torque | 4.889? ken D36A Printed in Japan ‘AOASOSS JCO3 3 cn ap ma LO Standerd | Weer limit = Main bearina]g=gi9997 | gua Nl inside da, ay Cap bolt (M12) Head width (17) f tighroring torgue | "808 hats SMID27A & D36A Sa, sae Be fe. soring os. naar soring F.0. teed pump, we a we LO ee Somes 19 the side cover sige fa lowe side Crank ait seo! ‘06 (Main bearing case)Chapter 3 Inspection and Service Procedures for Engine Parts 3. Piston and Connecting Rod aoe enone 3. Piston and Connecting Rod ‘+ The piston is of cast aluminum. A wear-resistant ting is, provided fo the 1st ring groove, and the cherry blossom ‘shaped combustion chamber is molded on the piston ‘crown, ‘The piston rings consist of the two compression rings, and ona oil ring, * The piston pin is full foating type. » The connecting rod is stamped and has -shaped stem with the large connecting rod end spilt horizontally ‘+ The crank pin metal is provided with a thin aluminum backing 41. Cautions when reassembling and servicing (1) Piston head and combustion surtace Remove the carbon deposit on the piston head and ‘combustion surface. Take care not 10 damage the piston. Check that there is no flaw on the combus- tion surface, (2) Measurement of piston outside diameter + Measure the piston outside diameter, and check the Wear of the ring grooves. If the size measured is below standard, or it they are excessively damaged, replace the piston. + Measure the piston outside diameter 20mm above the piston bottom and at a right angle to the piston pin, (3) Replacement ot piston pin + The fiting size of the full lating type piston pin is shown below. ‘+ Apply oil to the pin, and insert it into the pin hole at normal temperature (when the piston is replaced). (mm) iitens 27a D358 Piston pin hole | +0008 $0.08 inside diameter___| 2 9 20°F Piston pin ° 0 outside diameter 420-4 09 $25-o013 a PoE (mm) ST] standara | wear tit T | bates tos ] [(981.95 )+0.005, tee eset 2@ | io 0.005 fe | (L, Wor Sis punched on the piston heed) () for Exhaust vate Side recs i 1 Piston Piston pin Stop ring Printed in Japan ‘AOAS055 ICOChapter 3 Inspection and Service Procedures for Engine Parts 3. Piston and Connecting Rod cae ped (4) Measurement of piston ring ‘Measure the width and thickness ofthe piston rings clearance between the ring groove and the ring end gap. If they exceed the wear limit, reptaco tho ring, Handie the rings with care because the SUS nitride rings are brite, 1) Measurement of thickness and width of piston ring (mm) | Standard [Weer timit Thickness! 2 75 %10 —_ mi Piston rd G ring | width} a Piston (202388) sin tat ors Thickness] g, 4 2910 tee Piston ies | conascting cod Tia Width: ee — (20:92) | raaes “Thickress| 29020 a Oil ring nae Atigoment width| 3.6.00 _ " oesr-o0eo | ast 4 W2ringond | aaso-acco | 0. Oil ring and Gitring and | 0.020~0.050 ow Tor 6364, 2) Measurement of piston ring end gap ‘Connecting rod Insert the piston ring into the ring gauge. Measure the piston ring end gap with the gauge. (ram) eee Standard | Wear limit © “ }End gap of Nal. a2 | 0.25~0.95 ere piston ring (025~0.40)| |? T eee ion ing LF End gepofitring | 015~035 | 12 +t yer DER (testurement of ring end gep) 3) Replacement of piston ring Tasgigeit t0 mohors Fully clean the ring groove when replacing the ring. For fitting, the side with the maker's punched ‘mark at the end gap should be at the top. Check that the ring can be moved lightly ae (Fitting direction of ring) i Printed in Japan ae ‘ADASOSS JCO3Chapter 3 Inspection and Service Procedures for Engine Parts 3. Piston and Connecting Rod pete pie 2, Connecting rod (1) Cautions when reassembling and servicing 1) Measurement of distortion and parallaism of large and small end hole. Put ihe lips through the large and small end holes ‘of the connecting red and measure the distortion and prallalism of the connecting rod. Replace it if the size deviates from the standard. (mm) fins Standard | Wear limit 0.05 0.07 Parallelis™ | (For jodmm) | (For 100mm) (2) Measurement of inside and outside diameter of pis: ton pin and metal 1) Check the piston pin and metal for the seizure cracks and other damages. Replace it it exces: sively damaged. 2) Measuro the inside diameter of tho piston pin metal. Replace it if they exceed the wear limit. (mm) (eee Standard Wear limit wpe | | at outside diameter ° ) (926 Bo) 7 Piston pin metal 20 so.025 2 10 inside diameter 40.008 (26.10) Con) beeen | aasmaosy | 0? ©) for DIA (Messuring piston pin metal) an Printad in Japan ‘ROASOSS COSChapter 3 Inspection and Service Procedures for Engine Parts 4, Crankshaft 4. Crankshaft + The crankshaft is stamped, and comes in a monobiock. with the balancer. ‘+ The spline piace is press-ttted to the power take-off (bottom end} 1. Cautions for reassembling and servicing (1) Inspection of erankshatt Fully clean the crankshaft. Check itfor damages with a color checker or a magnetic flaw detector. If it is damaged excessively, replace it. Ifthe damages are light, repair the crankshatt (2) Measuring crankshatt distortion ‘Support the crankshaft journals by V-blocks at both fend, turn the crankshaft and measure the deviation of the middle journal with the dial gauge. (mm) | eee Stendard | Wear limit Seseee ee eee | Crankshaft distortion] <0.03 | 0.05 (8) Measuring crankshaft pin and journat Measure the outside diameter of the crankshaft pin and the journal. lithe wear (roundness or taper degree) is excessive, either replace or repair. When the outside ciameter is within the wear limit, consider to be adustabie, (mm) —— Standard Weer limit shettousde] *%t05 | 35.90 Gioeter | gag 2) | RD gl fete! | #8 ecm | nae ©) diameter | (aac) | (44-08) Slearance | (0.024~0'961) | 8) shattoutside| #49508 | 39.00 diameter (450 245) (49.90) El peering | e039 40.08 3] Taetiae | cqsocsttly | 6.08 oi oow~ooss | 0.5 Clearance | (0010~0.056) | @.16) a ©) tor D36A Primed in Japan "AOAS55-JCO3 ar MID27A & D36A Goring (APIO) Feather key ect / it eat (Crank shott)Chapter 3 Inspection and Service Procedures for Engine Parts 5. Camshaft MID27A & D36A 5. Camshaft ‘The intake/exnaust cams, the {ual cam and the journals of the camshaft are surface hardened and grounded. The camshaft drives the lube oil pump, linked at its end. Feather kay (5 12) pute 1. Points for reassembling and servicing j (1) Measuring outside ciameter of camshalt and inside R iameter of journal y - Measure the camshaft. I itis damaged excessively, (Cy) i replace it 5 ay (Comshett) | standard | Weer timit at ano x an] 00 | Camshaft 04) ors 40.9 outside diameter) (4 49-085) | (48.8) Bee cree Ee Lit (te) Camara | gat] journel insi oa at eign diameter 949 BOS) | (49-07) \ eee rece eee (Ee ereeeeeeee \ il clearence 9.050~0.100 0.18 SS ae (0.050~0.100) (0.16) 7 ( ) for D36A {Cam height) {Cam height) ai (mm) | Standard | Wear timit Intake cam | 94,986 height (H) (41,928) Exhaust cam | 34.965 height (H)| (41.928) I Fuel cam | 33.4368 | 0.1 height (H)) (42.943) (-0.1) ee 7) for D3 38 Printed in Jagan ‘ROASOSS JOOSChapter 3 Inspection and Service Procedures for Engine Parts 6. Cylinder Head SID ITA & IEA 6. Cylinder head + The integrated cylinder head for the 3 cylinders is built in the cylinder block. + Each cylinder has intake and exhaust valves, both fited with the valve seat insert 1, Cautions when reassembling and servicing (1) Inspection of combustion surtace for cracks ‘The combustion surface is used under severe con- ditions, including exposure to the extreme high tem- perature and pressure and also the low temperature ff the intake air. Check the combustion surface for discolorations, distortions and cracks with a color checker. (2) Inspection of intake/exhaust valve seat ‘Check the intake/exhaust valve seat for the contact condition and the width. If the seat surface width ‘exceeds the wear limit or the surface is 100 coarse, modity the seat (8) Procedures for grinding intake/exhaust valve seat Do the following procedures to modify the intake/ ‘exhaust valve seat with a seat grinder. 1) Seat specification Intake valve seat Angle : 45° Exhaust valve seat Angle : 45" ‘Standard interference (mm) — 1 7 Tpgtevete | goie—aon | wana a (Ioctving intkeresheust) 2) Be sure to measure the clearance between the valve land the valve guide, if modifications are needed. It the clearance exceeds the wear limit, replace the valve or the valve quide botore grinding, 3) Knead valve compound with oil, and grind the valve ‘soat with the compound. 4) Grind the valve seat with oil only '5) Altar grinding the valve seat, wash the valve and the cylinder head with diesel fuel oil carefully so that the valve compound or the grounded powder does not remains. Printed in Japan ‘AOAS0S5 C02 aChapter 3 Inspection and Service Procedures for Engine Parts S_Oplinder Head SIDA & IGA (4) Inspection of intake/exhaust valve and valve guide The cylinder head has one intake valve and one ‘exhaust valve (two-valve system). The OH. sys tem driven by the timing belt is employed tor the valve driving '* The intake and exhaust valves are mushroom-shaped with avalve head cap. 41) Inspection of valve stem for wear and distortion Check the valve stem for wear and distortion. 1 the valve stam is distorted or exceeds the wear limit replace it. (Also raplaco the valve guide at the same. time.) _feam) Sa case Ear a fees ee 00 | Yatgum tne] 47 oo | 88 (Mmessuring value stem) 2) Inspection of valve recess ‘After the valve has been repeatedly grounded, the valve recesses. Excessive valve recess atfects the combustion performance, Accordingly, measure the recess, and if it exceeds the wear limit, replace the valve and the seat. 7 (am) Valve recess Standard Wear limit Tintake | 0,250.1 05 27a; ——}— -}-———_-- Exhaust | 080201 08 Aintoke/exhoust valve recess) |Intake 0.250.1 | 136A} Exhoust| 0.45:40.1 07 Gis the projecting size 3) Measuring the valve quide inside diameter Measure the inside diameter of the valve guide. Replace it, if it excaods the wear limit. ra Printed in Japan ‘AQASOSS JCO3Chapter 3 Inspection and Service Procedures for Engine Parts 6. Cylinder Head 4) Inspection of intake/exhaust valve spring ‘= Check the intake/exhaust valve spring for flaws and corrosion. Replace the valve spring, if there are any flaws oF corrosion. ‘+ Measure the free lenath of the spring ‘© Measure the tension of the spring. (Use spring tension meter, if available.) + Measure the slant of the spring (the angle of the side of the spring) (mm) TJ standara | wear tit I S| Free length ga |e © (Guter/inner) | (43/40.7) | (415/39) & [Compressive torce (kot? 2.37 a ee Het 3 | stent 16 20 CT ) for O36 NOTE: The more dense spring painted is installed to the cylinder block side. (5) Replacing the valve seat The valve seat is cokditted to the cylinder block Accordingly, welding is suitable for removing a valve seat. [As shown in the right diagram, weld the seat remov- ing rod (an exhaust valve is attached later) to the weld-removing piece at three parts, and knock the rod to remove the seat Be sure 10 clamp the © side of the welder to the seat removing rod (shown in the diagram) when welding Protect the spudder on the explosion surface of the cylinder with tellon seats. (Rafer to the SERVICE NEWS 92MB-006.) Press-fit he valve seat with a ‘guide and a hammer (special tools). Printed in Japan "AOASD55.JCO3 MID27A & D36A suring the free length ‘of the spring i ) (Aviowaie tit value (A t Ay Istess than 0.03.) Surface plate “The ond of tha, shalt cog) Sest removing rod —>) iXn exhaust valve) | Should inter se port (Be (Coit san) ) ere (moar @85 20.1) (Seet removing rod) Le sure to clams See oe caer Seat removing r0d@ Cand S (Disposebisy Weld three points orth part (Seat removing method) anChapter 3 Inspection and Service Procedures for Engine Parts 6 Cylinder Head SIDA be DB6A, (©) Replacing the valve guide + Remove the valve guide from the inside of the cylinder to the valve arm case side. (The cylinder ‘might be scratches by the peripheral grooves on the valve guide if removed to the opposite side of the valve arm case, * Take care not to damage the clip on the intake port when removing the valve guide. + Prass-ft the valve guide with a positioning piece and a press-fiting tool. ‘+ Finish the inside Glameter of the valve guide with @ hand reamer (120270-99780) atter press-fitting oD L DIA | ast? | gat! pasa | aot | ast — 5 Nin (Removing tool 12027099770) (mm) Fee ea Standard | Wear limit oO Lots . 7) (Positioning the valve guide) Inside diameter Tt 19.000 of intakelexhaust| —@7 14 7.08 valve guide ban Clearance between inteke/exhaust valve) 0.035~0.005, 0.12 and valve guide NOTE: A valve stem seal is attached on the intake/exhaust valve guides. Replace the valve stem seal with new one if removed once, because it is not reus- able. As for 036A, the valve stem seals for the intake valve and the exhaust valve difer from each ‘other in shape, so be careful of the type of the valve stem seal. Use the press-fiting too! described inp. 23. 212 +e = (Hand reamer) teal the valve sem 68 (Geel eat ) Printed in Japan “AOAS055 COSChapter 3 Inspection and Service Procedures for Engine Parts ZValve Arm Case S87 27A & D36A 7. Valve Arm Case The valve arm case houses the intakelexhaust valve arm shaft, fuel valve arm shaft, camshaft, decompression device and breather. Cover 1, Cautions for reassembling and servicing ae (1) Measuring tne inside diameter of camshaft journal in ae valve arm case Measure the camshaft journal inside diameter. Re- Bearing place the camshaft journal, f worn beyond the limi (nm) Standard | Wear limit Bearing (6006) | 647 |-0.030 46.99 inside diameter |(55)| -0.050 | (54.99) Mid-journal | 41 | 90.025 «07 inside diameter |(949]| 0 43.07) _| {LO pum side ural 0.027 1 inside diameter | 26 | 0" 26.08 () for D36A (2) Use new packings, oil seals and O-ring (3) Do not remove the plugs or the blind caps except when necessary. Clean the camshaft journal, bearing (6006) and valve arm shaft journal carefully before instaling, « (Valve erm case) Printoa in Japan ‘ROABOSS.JCO3 aChapter 3 Inspection and Service Procedures for Engine Parts 8, Intake/Exhaust Valve Arm and Unit Injector SMID27A & D364 8. Intake/Exhaust Valve Arm and Unit Injector + The intake/exhaust valve arms are rocker-lever type. ‘+ The walt injector driving valve arm is rocker arm type, and the roller type is used for the cam contact side. 1. Cautions for reassembling and servicing (1) Measuring outside diameter of intake/axhaust valve arm shaft and inside diameter of intakevexhaust valve arm Measure the outside diameter of the intake/exhaust valve arm shatt and the inside diameter of the valve arm, Replace the intake/exhaust valve arm shatt or the valve arm, if worn beyond the limit (nm) aaaasecs, Stenderd | Weer limit 38 Intake/oxneust valve arr) shalt oursiga diameter 15.90 +0018 91679 Intake/exhaust valve arr) inside diameter bases 4.005 (#1825012 Clearance betwoon vaive| farm shalt outside diam eter and valve erm inside Siameter 018-008 | (@.o0t~o.000)} 013 (Ofer O38 (2) Measuring outside diameter of injector driving valve ‘arm shaft and inside diameter of valve arm ‘+ Measure the outside diameter of the injector driving valve arm shaft and the inside diameter of the valve ‘arm. Replace the injector driving valve arm shatt or the valve arm, if worn beyond the limit. : (um) eet Standard | Wear limit Unis intr erving | #1890 eas Comfy (21-88) Unit injector ariving | 416°" | se gn valve arm inside : diameter Gq20t9om | (22.08) Cran bee va a 0.016~0.052 ‘Ghearm nae dma (2.008~0.08), OTP ( ) for D36A ‘+ Inspection of injector driving valve arm roller ‘Check the roller pins on the injector driving valve arm. Ht flaws, cracks, or wear is excessive, replace the pin, (mm! Nominal | Wear limit Roller pin outside diameter $7 7 bind eae ae 6 Rasyaine g —x (Lemar, 4 dy on se | ter Wg Spring Intake valve 8 se a em ‘gta Seas at Wy So — sna i Herat | ee (Ditterence of sate arm) Fre intake “valve arm ie fucted at the adjusting Prins in Japan ae "AOASOSS-JCO3Chapter 3 Inspection and Service Procedures for Engine Parts 8. Intake/Exhaust Valve Arm and Unit Injector ane iGEt (3) Measuring top clearance Measuring procedure ‘a, Remove the unit injector. b. Turn the flywheel to position the piston at ap- proximately 20° before the top dead center. fc. insert the measuring fuse (1.0mm diameter) ‘through the unt injector installation hole, and place the fuse at the position illustrated on the right (The space is too small to accept more than one fuse.) 1d. Turn the flywheel in the rogular turning direction (clockwise viewed from the flywheel side} to po. sition at approximately 20° after the top dead center, and take out the measuring fuse. ©. Measure the thickness of the pressed measuring fuse with a micrometer. Exhaust valve (mm} Standerd 27a 060° Top clearance | 36a _0.55*% (4) Adjusting valve clearance of intake/exhaust valve head Adjusting procedut ‘Take out the unit injector valve arm retainer. ‘a. Adjust the clearance while the engine is cool b. Position the piston at the top dead center of the combustion stroke. (Top compression) . Loosen the adjusting screws and nuts ofthe intaker exhaust valve arms. <4. Adjust the clearances between the intake/exhaust valve heads and adjusting screw heads 10 the specitied value,lock the adjusting screws. NOTE: 1. Make sure that the caps are installed to the intake/ ‘exhaust vaive heads before adjusting. 2. Refer 10 p. 3-29 if the timing gear pulley is LO screweriver disassembled. ox, oy ale er (mm) — lander — Siena Ctooronce eauge 0.2mm Intakevexhaust | [tee oF valve head clearance [Posy ie ( sesrerea'aafiettese"***) Printed in Japan ie ‘AQASOSS JCO3Chapter 3 Inspection and Service Procedures for Engine Parts 8. Intake/Exhaust Valve Arm and Unit Injector Seamed pact (5) Adjusting fuel injection timing ‘Adjusting when the unit injector Is installed on the engine Install the unt injector on the engina. Align the scale of the flywheel to the spectfied injection timing. Turn the adjusting screw until the tappet line matches up the alignment line on the injector body viowed from NOTE: For adjustment uso a deflection mirror. A (ilustrated on the right diagram). Fix the adjusting screw with lock nuts. Standard NN 308, Oza Fuel injection timing (FIC) | STDC | eto 12° Ineiestor 15° for D954 Pye ling 10 tienen) Indicator 2 for 0278 Any contro over position may be accented. (Gaceuse the plunger hos no top Seed) a6 et Fc! x (nese on ns injector (Adjusting {vel injection timing) Screwdriver Sere ia E.On valee seen Printed in Japan "AQASOSS-JC03Chapter 3 Inspection and Service Procedures for Engine Parts 9 Thermostat \M/D27A & D36A 9. Thermostat Two wax-pallet type thermostats of the same shape are installed to the cylinder block side cover, one for the water temperature and one for the exhaust temperature. These thermostats keep the temperature according to the water temperature and the load 1. Cautions for reassembling and servicing (1) Inspection of thermostat ‘a. Place the thermostat in a container filled with water. Measure the water temperature with a thermometer while heating the water. If the valve opens at the (sigpe volvo, thermostat cover) specitied valve opening temp. and opens fully at the eet ‘specified valve ful-open tomp,, the thermostat is good. I the valve opening oF full-open temperature of the thermostat differs from the specified tomp., replace the thermostat. Pea Stendard temperature °C en Wane Valve YANMAR code No opening temp. | ullapen temo natu 70 src 20270-49191 Exhaust temp. | sgyeTr aaa Exhausl feme.| goo ee | 1aoaTo-48700 b. Use new packings and sé «. Tighten the bolts (M6 X 25, M6 X 50) at the specified an 7 an (nex, wate) wien 10) Fe eer Snat gait Ney 4. Remove any dt toate thomas es iisie mere) eae ‘AOASOSS.JCO3 arChapter 3 Inspection and Service Procedures for Engine Parts 10. Unit Injector MID27A & D36A 10. Unit Injector ‘The unit injector is an integral part of the fuel injection pump and the nozzle, and is installed to each cylinder. = Pump; Bosch type control system (by control lever) = Nozzio : Sealed automatic valve, wheel valve 1. Speeitcations Metype unit injector Pump type - 36a 027A Plunger | diameter || ¢7 | #8 Nozzle injection) |g ee aaait ete Sa | en | 5 90.22«168" | ¢-90.20% 160 Prostroke | me 30 26 camiitt | me | 70 65 Fusivave | hal7 Ste ee) opening presure| ef | 200 (Unit injector) (Hisresiattl my — |_| aaa 1 —, f ger baie << iat Plunger barrel aa ee fae ‘ADASOSS JCO3Chapter 3 Inspection and Service Procedures for Engine Parts 10. Unit Injector ann enial 2. Disassembling the unit injector Disassemble and adjust the unit injector body at a service ae shop. aeneaae Follow the procedures below to check the opening valve Nozse soe pressure adjustment and the spray form of the nozzle. fist (1) tsgcton of mat astonty a. Caton toner site |. ‘A phenomenon that carbon sticks to the nozzle tke | a flower is called carbon flower. As carbon flower pa i reduces combustion performance, remove the car HH bon it any | ». Spray shape Nossa essemi 41) Check the spray with a nozzle tester. 2) Normal spray shape [ilustrated bolow) * No excessive angle daviation. + The spray is fine mist Noss out + The spray stops instantaneously. (Nozzle disassembly) \ Das D278:150 D368: 185° (Normal spray shape) (2) Adjusting nozzle valve opening pressure : TE Adjusting shim 1) Remove the nozzle from the unit injector. i None spi 2) Install the nozzle to the adjusting holder Reece Assemble the adjusting shim, nozzle spring, spring ran ree seat and stop plate, and install the assembly A soxing set it [[Terwningtorae | so-aseatm | t pene ee eeeeeeeee (Disassembling the nozzle essembly} Af win Nozsle nut Noss escembly (Aaiueting holder essombly) Printed in Japan a ‘AOABOSS-JCOSChapter 3 Inspection and Service Procedures for Engine Parts 10, Unit Injector 3) Test with a nozzle tester. Valve opening pressure! 200° agf-eed NOTE: It the nozzlo assombly has been used less than 500 hours, the pressure is hardly changed by re- lacing the nozzle assembly. 4) Adjust the nozzle valve opening pressure. eee Measure the depths of the insoried parts of the unit injector body and the spring bracket. Adjust the pres- ‘sure by increasing or reducing the thickness of the ‘dusting shim, i Compare the depths of H and Hi illustrated on the | fight diagram, and adjust the thickness of the ad- | justing shim (described below), ——— CO NOTE 1D_ [Shim thickness| 1. The ID. is displayed =] es ae with permanent ink. 70-aan20 8 0.38 2 0.1mm adjusting shim| 0.40 20 katiem? valve open Gucritaeae eal ing pressure. 4 9.46 9. Use one adjusting shim, (2 or more adjusting | 88) | | shin are torbiacen.) 8 0.55 Valve opening pressure 120270-99010 adjusting holder [Confirmations] Confirm the following betore installing to the unit injoctor body: Install the nozzle adjusted at 200+ Skgtiom? with the ad- justing holder, spring and shim to the unit injector, Tighten the case nuts after readjusting Ht and H Example: (1) Dimension of shim adjusted at 200 + Skgt/om? {shim thickness of nozzle valve opening pressure adjusting holder) (2) Dimension of H (depth of injector body nozzle spring case) (8) Dimension of Hi (depth of nozzle valve opening pressure adjusting holder nozzle spring case) (0.45 + (13.95 - 3.90) = 0.50 (thickness of shim in unit injoctor assembly) NOTE: Roplace the packing, protector and O-ring with new ‘ones when installing the unit injector to the engine. 320 2 = MID27A & D36A ie ase [a] (injector body) (Aajuning rts vomn-sai0 ——| ‘incteases or reducos| Stonderd sire 0.45, 13.95 13.90 Print in Japan ‘AQASOBS JCODChapter 3 Inspection and Service Procedures for Engine Parts 10. Unit Injector Meas Pa (Procedures for adjusting nozzle valve opening pressure) (1) Install the unit injector holder to the vise base. (2) Set the unit injector to the holder. (@) Loosen the case nuts, and remove the nozzle from the unit injector. (4) Install the nozzle to the adjusting holder. (6) Install the adjusting holder to the nozzle tester, and ad- just the valve opening pressure with the adjusting shim. Printed in Japan a "ROASOSS-JCOSChapter 3 Inspection and Service Procedures for Engine Parts 10. Unit Injector 3, Removing unit injector (1) Be sure to remove fuel oil oF to tit up the engine before removing the unit injector (to prevent fue! leak at the fuel pass}. (2) Align to the overlap position. (3) Loosen the injector fixing bolt, and remove the re- tainer. (6-mm hexagon rod wrench) {4) Down the FO valve arm. (6) Screw a fixing bolt, and lever the cut of the injector Up with removing tool using the bolt as a supporter. 4, Standards for servicing (unit injector) (1) Reference of standards for servicing ee oxagorat hole bolt ME 1.25 (2) Adjusting tools Tightening sore Removing too! -SMID27A & D36A enone wl] Glenrance £0.13-0.18m TE-Eeegtn| Deon Tiantening torqu Sree eran ing 1190270-59360) ees ing (sa0ern- 53360 cashes (17070-1170 ~~ protector (12070-11801) Na Name ary Remark Na Remark 1 | Nozale tester fet sian 2| High pressure pipe | 1 127610" 93400 High pressure pina) Slide caliper Commercial tool tun ah ese | Unit injector holder 20270-92020 ‘Torque wrench iorhtdeieictan tol Nozzle valve opening zi u (90001) 1 |e ca e pressure adjusting holder Hee eoe oat 4 | Box wrench 1 [Gommerciat tot 1 9 | vise base 1 | Commercial toot 5 | Spanner 2 [Commercial tool 10 | ie Prinad in Jga0 ‘AOASOSS-JOOSChapter 3 Inspection and Service Procedures for Engine Parts 2O.Unit Injector S274 & DB6A 5. Fuol toed pump (1) Specifeations @ @ o rpm. 3800rpm ®. i Feeding guonity ]1.3 ¢/min or more sa | 3) Shaft (FOP) a 4 | inner rotor > sa | 1 5 | Outer rotor » sao | 1 6 | Pulley (Beering) { — $2800 T 7 | Pulley (cay } 52811 1 | ry (cap) | Bi Plate 1 | Binding ral sare i tal (M3 x 7; tt 10 i Oil seal 1 11] O-ring aeaii—scca20 | t 12| Hexagon plug zaae7—oe0002 | 1 18] Seal woshor aaun0-sooaro | 1 14! Soring reoon-szse0 | 1 18| Stee! ball 3/16) 24190-60001 | 1 Prnted in Japan a ‘ADABOSS JCO3Chapter 3 Inspection and Service Procedures for Engine Parts 11. Governor 11. Governor ‘The governor is a 3:point weight mechanical al-speed governor. Also this is a floating lever type governor driven by the timing belt, and instatled to the cylinder block ‘Tho governor weight assembly is driven by the timing belt ‘pulley and controls the unit injector contro! rod via the governor lever to control (increaseidecrease) fuel injection volume. 1. Cautions when reassembling and servicing (1) Inspection of governor To protect the engine, the governor is adjusted to the specified output and engine speed, and sealed and locked with fixing wire. Accordingly, do not disassemble and adjust the governor unless neces: sary. Improper adjusting of the governor causes engine troubles or operation failures. Q When the governor is disassembled, check the following: 2. Governor weight pin Measure the outside and the inside diameter of the governor weight pin. Replace the governor weight, pt tis vo. (mm) “| Standard Wear limit Govenor waht | sa pinousige "| 9 70m 09 terete Governor weight | cay ere a iiteectie 619 diameter } i b, Thust needie Check the thrust needle for seizure, discoloration or damage. Replace any detective thrust needle. c. Governor spindle and governor weight support Check the outside of the governor spindle and the inside of the governor weight support for seizure, discoloration or damage, Replace any detective ‘governor spindle or governor weight suppor. SMID27A & D36A & (Governor assembly) Qu cS. Stop ring € {hole 42} Governor weight Pin, Split pin (2.0 10) ae Governor weight (Governor) Prioted in Japan ‘ROASOSS JCO3Chapter 3 Inspection and Service Procedures for Engine Parts Ht Governor SMID27A & D36A 2. Adjusting procedures when reassembling (1) Adjusting unit injector injection volume on each cyinder 1) Press and fix the control rod against the end surface of the cover (start SP) with a fixing jig. Gover (start SP) ans Contra 103 Finite 9 Fixing fio 2) Tum each of the unit injector control levers to the ‘ue! increasing side. Fix the adjuster to the control rod with a hexagon hole bolt and a washer, while pross- ing the lever against the side of the tappet. NOTE: Check the control lever for any play by moving the lover. Readjust the contro! lever, if necessary. The clearance must be 0 for all three control levers. Hexagon hole bolt (M4 18) = i jghtening torque 0.08~0. 11h Pnted in Japan ‘ADASOSS JCOS 325Chapter 3 Inspection and Service Procedures for Engine Parts ais Gorermer, ;MIDI7A & D36A 3) Remove the fixing jg, and make sure that the control rod moves smoothly. Exstosion (2) Adjusting regulator spring assembly 1) The fiting load of the regulator spring is already adjusted at our plant. Do not remove the assembly. ‘When the no load speed cannot be raised to more than 4800 rpm, add the adjusting shim to agjust the speed 2) Check the installation longth of the idle spring. Make sure that the stroke is 4 +0.3 mm alter setting the idle adjuster to the dimansion ¢ (1 = 6 mm), 3) Set the spring (A) at its free length to the idle spring retainer. Make sure that the stroke of the spring (A) is 2 0.3 mm, belore reassembling It to the regu- lator spring caso, (3) Adjusting the governor 1) Max. speed ‘Screw in the regulator spring case manually uni it contacts the governor lever 1. (This the medium speed spring, not where itis tuly socewed in with a wrench.) Then, unscrew the case by 25 turns (5 mm). The max. speed 4800 4900 rpm should be obtained at this position. f the max. speed ‘can not be obtained, screw the case in further Max. injection position 2 aN (Regulator assembly) Printed in Japan ‘AOASOSS-JCOS 228Chapter 3 Inspection and Service Procedures for Engine Parts 41. Governor 2) Min. speed Protrude the idling adjuster 6.0 mm from the case end. ‘Idling fine aduustment : Make fine adjustment with the idte adjusting bot, and set the speed to1000 rpm. “+ Max. load adjusiment : Adjust to 4500 rpm with the fuel regulating bolt during cruising oF by installing the load equipment. ;MID27A & D36A Regulator spring case lole eajusting F.0. mit bol ee (4) Adjusting governor fink 1) Adusting regulator cable ‘Tum the steering handle gripin the increasing direction, and tix the grip at where it contacts the stopper ‘Adjust the regulator cable so that the alignment marks. ‘match up. (About 25° trom the vertical line level.) 2) Adjusting regulator rod length a) Turn the steering handle rip in the increasing direction, and fix the grip at where it contacts the stopper. »b) Screw in the rod spring stop nut until the regulator lever reaches the max. position (where the nut con- tacts the limit bol). ©) Further screw in the stop nut by 2 tums (about 2 mm), and fix the nut 3) Adjusting reverse rod length Turn the steering handle grip to the max. speed position. Adjust the cloarance between the reverse lever stopper and the bracket (shift) to approximately 2 mm at the max. speed position Printed in Japan "ADAS05 JCO3 ser Regulator spring Coble (uel ext) od (regyteror) Overense cose crepulerory Rod (roles) XE: Work angie about 80" BED Se'engle sbovt 23° ble (decem. Cable regulator) Rovarse mat. speed | adustment bolt een Levor(raverse} ‘Bracket (shit) ©)Chapter 3 Inspection and Service Procedures for Engine Parts LL. Governor ana (5) Adjusting engine speed ‘Adjust the iding and the max. speed to the speciiog Max. speed position (provler output) load applied to the propeller shaft of the outboard (Engine ovteut i ite fa oar fag 1) Adjusting the ing speed (1000 rpm when the engine is warm) ‘Shift the clutch to the neutral position. Adjust the idling speed with the idle adjusting bolt so that the engine ‘speed is in the range of 1000 ~1050 rpm, and lock. s ‘he bolt with nut Nut (MB) tightening torque 2) Adjusting max. speed (4600 rpm) ‘© Shift the clutch to the forward position. Adjust the max. speed with the fuel limit bolt so that the engine ‘speed is in the range of 4400 ~ 4800 rpm, and lock the bolt with a nut. ‘Nut (MB) | width ot tightening torque 0.8~1.0kgf-m ‘+ Fasten the nut 10 the fuo! limit bolt cap nut with a fixing wire (20.6 mmn), and seal it. Printed in Japan ieee ‘AOASOSS COSChapter 3 Inspection and Service Procedures for Engine Parts 1. Governor SMID27A & D36A (6) Procedures for instaling timing belt 1) Removing the timing belt a) Install the fixture to the flywheel, and toosen the flywhee! fixing bots ) Remove the fiywhee! with a flywheel removing tool ©) Remove the generator, loosen the belt tensioner of the feed pump, and remove the timing belt Toraug wronch < bon dbenn Fixing jin NOTE: To remove the timing belt, align the marks as shown in the ilustration 2) Instaling the timing belt 2) Align the crank gear alignment mark with the cam pulley alignment mark, and set the bait M8 ote pcs ) Tighten the feed pump tensioner. Elbe rmosing Adjust the tension to 15kg with a batt tension gauge ‘+ Roused belt: Measure the tension with a belt tension gauge bofore removing the belt, and adjust the tension to the measurement after Instaling tne belt. Or mark on the tensioner and the cylinder be- fore removing the belt, and adjust the tension by aligning the marks after installing the belt (Do not clean the belt with grease or cl.) ©) Install the generator. (Apply screw lock to the installation bolts.) 4) Install the flywheel Box wrench 36mm) 2Bagf-mn Model Belt code Size Aligoment 111R25 mare 036 | 20980-01830 | (gait wich 25) wiRa para | raoae-ous0 | (ggitR'® 5, yi mh a [rsp nr oy ° samen (hg, STS gone Gfx £0. tt ue ecu: Ped n pan ‘AOASOSS 1003 3Printed in Japan ‘AQASOSS-JCO3 CHAPTER 4 REASSEMBLING AND SERVICING OF DRIVE UNIT ‘SwivelSteering Bracket .. Clamp Bracket... Upper Case Bottom Gowing and Fiting Pants .. Lower Gear Case... Cooling Water Pump and Cooling Water ona . Steering Handle ae fae 46 5. Hydraulic Cylinder ene el ae Electre-Hydraulle Tilting 418 Connecting the Upper Case with Steering Bracket ... “ eeChapter 4 Reassembling and Servicing of Drive Unit 1. SwivellSteering Bracket epee E bse 1. Swivel/Steering Bracket ‘The swivel bracket is connected to the clamp bracket with the tit tube, and supports the steering bracket with the pivat shatt. The pivot shatt bearing is sealed and is equipped with the brake, The steering bracket is separate from the handle bracket or the lower mount bracket, and is con- nected by a spline and a stop ring, 1. Cautions when reassembling and servicing (1) The steering bracket is separate trom the pivot shatt 2) Swivel bracket a. Install the friction plate, bush (45 X 30), O-ring and: washor in that order to the upper part of the pivot shait hole of the swivel bracket. b. Install the pivat shaft to the pivot shaft hole of the swivel bracket, (Install the upper bush) «. Install the bush (80 X 44), seal (V030408) and washer in that order to the lower part of the pivot shatt hole of the swivel bracket | Standard Clearance between bush inside dia. and om 1 Amm: outside dia 4. Install the lower mount bracket and a washer stop ring. (Swivel bracket) (Lowor mount) Printed in Japan i "AOASOSS ¥CO3Chapter 4 Reassembling and Servicing of Drive Unit 1. SwiveliSteering Bracket rer ¢. Tilt lock lever ‘The teassembling procedures and the parts are not the same for manual tiling and the hydrautec titing (Refer to p. 4-18.) Cautions when reassembling each parts are described here. 41) Fit in the left and right tit lock levers. Standard Clearance between tilt lock lever shaft outside dia 0,06~0, 174m and bearing inside dia. ‘Set washers, return spring, collars, tit spring hooks, ‘and tilt stop levers to the both ends of the tit lock levers (L and A). Match up the hole of the tit lock levers (t and A) and the collars, and fix them with spilt ping (3.2 X 2.5). Before fixing, hang the return springs on the tit spring hooks. 2) Fasten the tit lever bolt to the return spring and the tit spring hook, and set the assembly to the tit lock levers. NOTE: 1. Supply grease to the pivot shalt, tit lock lever, ‘shaft and the tit lever bearing pars. Recommended grease COSMO GREASE DYNAMAX EP No.2 or equivaiont 2 Install the bush (30 X 39) to the swivel bracket in advance. Standerd Clearance between bush outside dia. and bracket 0~0.2508 hole inside dia. 7 Printed in Japan "AQASOSS ICOChapter 4 Reassembling and Servicing of Drive Unit J. SwivellSteering Bracket TT f. Install the assembly to the half tit armi {nstall the haf tit spring (and the stopper) to the hnook. (Option) 1. Install the tit stop rod to the tilt stop lever. Install the shock absorber to the swivel bracket. Install the spring and the tit stop rod to the absorber lever. h. Install the steering brake cover, brake spring and collar to the swivel bracket in that order, and tempo- rarly tighten thom with brake bolts. (The steering load must be adjusted after instaling.} (Shock absorber) Handle bracket Pivot ena 6 amg, ‘Swivel bracket - Mount rubber Prieta fo Japan RORSOSSICOS 43Chapter 4 Reassembling and Servicing of Drive Unit 2. Clamp Bracket SMID27A & D36A 2. Clamp Bracket ‘The lett and right clamp brackets, which are made of alu- minum, make a pair. Thoy are bolted to the transom 1. Cautions when reassembling and servicing (1) Clamp bracket 1. Install the clamp bracket assombly to the swival bracket, and sot the lett and right assembies with ‘the till tube and support bol. Install the assembly {ne either to the shock absorber or to the support bolt ‘of the hydraulic cylinder. Tilt tube nut tightening torque 2.0egf-m e ». Install the thrust rod. Check the tit-up foad (iting start position at moiding), and the tiitup angie (angle to the transom plate). (Tile tobe hole) ‘Also check the hal-tit function —— Standard Tilt-up load ve rat | tcaven (EER aati | aS | Setanta | wo La ay NOTE: Fill hydraulic oil up to the filing port with the unit {ited up to the maximum. (eenussmnor (Piping) {Instell the flare tube) Per} Printed i Japan ‘AOASOSS-JCOS.Chapter 4 Reassembling snd Servicing of Drive Unit 9, Electric-hydraulic Tilting SMID27A & D364 (2) Procedures for suppiyng power unit o 1) Remove m —— ) Remove the plug from the (A) part, (o — 2) Tit up and down 4 to 5 times wile eupptying of ("8 though the plug hole using an oll fier. F 3) Wen th ol tons entering, up tothe plug hole at ne wtp poston, ara epren ep, Won d\ Changing al reve the power wn and pur out tre ol om ho (8) par. Howovar, changing os I almost unnecessary, because the oil hardly deterio- fates (9) Procedures tor power tit manual operation If the engine cannot be tited up or down due to a trouble, ln counter clockwise (loosen) the manual valve on the (B) part with a © screwariver to open both the down side and the lap side of the hydraulic ‘itcuit, Then the engine can be tied up or down, manually, In this case, lock the engine in the tited position with the manual tit lock lever. (The ‘manual tit jock lever is used only in case of emer- gency.) JF (A) connected to Seay bor (8) Manvet voive Printed in Japan ‘AOASOESI0OS aChapter 4 Reassembling and Servicing of Drive Unit 10. Connecting the Upper Case with Steering Bracket MIDITA & D36A 10. Connecting the Upper Case with Steering Bracket ‘The upper case and the steering bracket are bolted together through the mount rubber. They are bolted at two points: Upper and lower. The upper point is the steering bracket with stopper brackets (left and right brackets differ in shape), and the lower point is the ‘ower mount bracket with the damper. (Steering bracket} {Upper point of bolting) Flenge meunt 5 (Uover case) rubber Mount rubber Upper sige. Soscer mount ‘o-ring te SR ey Fé, (Lower point of bolting) Damper lower Mount rubber SP Damper lower reverse Mount rGbver fs (Esme Stopper) (install the mount rubber) Seen ee {Lower mount bracket) Print in Japan to ‘ROASOS5ICOSCHAPTER 5 PIPING DIAGRAM 1, Piping Diagram ..csrnnnninnunnnnnChapter 5 Piping Diagram 1 Piping Diagram SMID27A & D36A 1. Piping Diagram (1) 027A Smet [Hom oct tork | Fucl oil pipe a £.0. pige connector I saan y —tH— | Screw joint Fuel pressure control valve SH | Flange joint vate 1 __ to eamehate — i Water ter Auber hose pa el ' Exnaust to. | xzort | Aluminum oe iat ee ee \ w THM Titanium pie ee Lube 01 puma ua ter : careidan type Lube oul hte = cartridge tye Water checking Main besrieg moe art Lube oil pressure cootal valve Lupe il Hiller wos TrHI5W ooling water pump . see Son water inlet See Thermostat valve opening temp. Water temo. thermostat no wo Exhaust temp. thermostat 65 we +9 ane 8 #85 Ey mo tea er t 8) I 7| 7 ons Details of A Details of 8 Details of © Details of D NOTE: The pipe dimensions in the diagram above show inner diameter X thickness for rubber pipes and ‘outer diameter X thickness for other pipes. Printed in Japan ma ‘RORSOSS JCO3Chapter § Piping Diagram 1. Piping Diagram MID27A & D364 (2) D36A, Symbo! Nome —F— [atic < Sigat int Water temp RH Rubber hese sad 5RH ety dae aT Exhaust em. ual injction vue ‘Teer Esl filter cartridge yp Water checking 2x08 azo 6xt05_ THES Sooting water pump : $89 water Sea wBtor ile Boe water out ‘Thermostat valve opening temp. Weter temp, thermostat wo ate Exhaust temp. thermostat 0 10 on5 one ous i Ei |. i. Fie oa | Details of A Details of B Detaits of C Details of D NOTE: The pipe dimensions in the diagram above show inner diameter X thickness for rubber pipes and ‘outer diameter X thickness for other pipes. Printed in Japan oF ‘AOASOSS-JCO3CHAPTER 6 ELECTRIC EQUIPMENT i a ee 2. Sta fae ‘ore (Reducton neu) 3, Wamning Device 4. Wing Diagram .. Printed in Japan ‘AOASDSS-JCO3Chapter 6 Electric Equipment 1, Generator 1. Generator 1. Specifications | YANMAR ef YANMAR | s20390-77221 Charging | Full wave rectification, specification load 10 + O.5A at 14V, Charging 00 rp. beadilid (at normal temperature) Charging | Less than 1000 r.p.m. start speed | at battery voltage 13V Ambien tomperature | ~27C~ 650 [yee 6055 made by KOKUSAN DENK Direction of | Clockwise Approximately 1. the (viewed from flywheel side NOTE: Apply screw lock to the rotor mounting bolt (ME X 22) before installing. 2. Regulator Type ‘SU2KBY made by KOKUSAN DENKI Control system] AC half-wave short-circuit control YANMAR fm YANWART yao3e0-77720-1 Combination || amp toad: 13.0V 40M Combination | Battery :12.0V T0AH load (full cherge) weight | 160g (nstail the reguistor) Printed in Japan ‘AOASOSS-JCO3 6 ;MID27A & D36A “ide : é V205t (oh line on green i 2054 arse) es C0108 (tin-lote) % nn a Stone YAZAKI Corp, 7170-1151) Out current characterises {ot UV) (Ble Ses cere er a0 op 1 = » a “| 4 a] | yf al 2 } a Lang oa ee wes] rer-wtiel 3 oe OEY BL bnew a cette ts we EY, 44 wv resChapter 6 Electric Equipment 2. Starting Motor (Reduction Gear) SMID27A & D36A 2. Starting Motor (Reduction Gear) +, Specifications 1) 027A 2) D36A Type S114-A51A mage by HITACHI Type $116-877 made by HITACHI YANMAR = YANMAR Ee ot YANN 120370-77011 oo vao3e0-77070 Nominal output 1.204 Nominel output 1a Cirout voltage nv Circut voltage ev Rating d0see Rating see Direction of Counterclockwise Direction of Counterclockwise rotation (Sewed trom pinion sige) | rotation {Wewed trom pinion side) Circuit system] Body grounding Circuit system! Body grounding Cluteh system Roller clutch Clutch system Roller elton ‘Number of [Tooth end [Number of | Tooth end], teeth 8 |diameter | 226 teeth 8 |diameter |_#29-6 [Pressure Fite ei «-|Pressare” [pgp [Pitch ert S|engle ae diameter | 22-86 8 |angle 2" diameter | $22.85 E|snitt [99 [Tootboron] a9 > E | shitt tay [Taothbotion! 9 25.9 [avancity | 27 |diometer’ | # quannity Gamer |_* \ Patera Oeste) «ava Hardness |HRCS8~69 conte | 12.499"? Hardness HRCS8~69 ORs 7 40. Pinion shi inion shit en Torsion spring system Poona Torsion spring system Weight a3 Weight “3 2l/8le lg og charactrite of a|2lg {8 faery (NRRCISS Hetaroe Sorary HPSS 2/213 |2 — nea2-90 Henerae whigatramiy 2] 30 ee so| 20] a0 oa 16 em 06] 12 | a0 oa 08 | ano 02} 08 | ro al ol 0 10 xO 50D aM BOD E00 TO oH oo mm nm sm oO Cureent (A) Current {A} (Standard output characteristic curve) (Stondard output characteristic curve) 7 Printed in Japan ‘AORSOS5ICOSChapter 6 Electric Equipment 2, Starting Motor (Reduction Gear) 2, Structure and functions a @ 3 4) Starter The reduction gear is placed between the armature land the pinion, and the motor torque is increased and transmitted to the pinion. Reduction gear The small gear installed on the armature shatt tip always engages with the large gear on the clutch circumference, and the rotation of the armature is transmitted through the reduction gear and the clutch 40 the pinion, Pinion shift system The pinion shift system is a torsion spring system. The system consists of an outer clutch, a roller and fan inner clutch. The clutch is fixed with a ball bear- ing, and the pinion shaft is pushed into the inside Of the inner cluich through the helical spline, causing the pinion to engage with the ring goar. Roller cluich The roller clten consists of a roller, an innos clutch and an outer clutch. The roller is always pushed by the spring, and retained in the direction of the shorter dimension of the outer clutch . When the roller turns in the cirection of the tonger dimension of the outer Cluteh, the outer ciutch rotates ily. When the rollar turns ‘in the narrow direction of the taper. the clutch inner and outer combine and transmit tho rotation Printed in Japan "AOASD5S.IC03, 63 SMID27A & D36A Magnet Through bot Ups nol Grease (Structural gisgram) Starting switch ing motor wiring diagram)Chapter 6 Electric Equipment 3. Warning Device 3. Warning Device 1. Details of warning device (1) The alarm buzzer turns ON from abnormality such as insutficiont hydraulic pressure, overheat or poor battery charge. (2) The alarm lamp turns on trom insufficient hydraulic pressure only. It the alarm lamp is OFF and the alarm buzzer is ON, the cause is overheat of poor battery charge. {Standard specications) Alerm buzzer ‘Alarm lomp insulficient draulic pressure ° Overheat ° = | Batery charge ° oe Arbiteary | Installing place ta 3m_ | Standard postion from bottom cowling Battery charge ° Installing place (pion) For Type & (p. 6-8) and Type C (p. 69) | Alarm buzzer ‘Alarm lamp insufficient hydraulic pressure BOE HH 2 Overhoat ° indicator panel 64 SMID27A & D36A Printec in Japan ‘AOASOSS-JCO3Chapter 6 Electric Equipment 3. Warning Device SMID27A & D36A 3 Warning Device 0's 2. Functioning of warning device (1) Turning kay switch ON causes the alarm buzzer and the alarm lamp to turn ON for approximately 2 sec. (2) lt you leave the key switch without starting the engine ‘ot approximately 180 sec., the buzzer and the lamp turn ON again, When you start the engine atter that, the buzzer and the lamp turn OFF. Functioning chert r ou pe ker sw. ool L Engine tort BRUNE srori_IU Le Pr Lo. yarautic pressure OPEN ow Lose. Rep. ‘cylinder nead tom (ovrtest tam) OM Keguiator lam ea Peper ti) 28 it temp ON . OFF Prt pan i ‘AOASOSS.JCO3Chapter 6 Electric Equipment 4. Wiring Diagram (+ poses eo 20 40s yO pu801D) ¢ eo1nop Bujusem yim odd pepuers Jo wesBerp Busi (L) weibeiq BuliM ‘p ‘AORSOSS- JOOS Printed in Japan 66Chapter 6 Electric Equipment 4. Wiring Diagram Serer (2) Wiring diagram of type A with warni Print in Japan ‘ROASOSS JCOS er‘AOASOSS.JCO3 Chapter 6 Electric 4. Wiring Diagram ooinop Gujusom yim q 94K) Jo weiBerp Bulsim (¢)Chapter 6 Electric Equipment 4. Wiring Diagram /MID27A & D364 saves win 2} : 4 Z 4 Sy ake. Jf 4g i ae * id § 1 i £ i - a Oe 3 ¢ | )# : z Pad pan ‘AOAEOSS JC03Chapter 6 Electric Equipment 4. Wiring Diagram ;MID27A & D36A vn wen i paspam oa ye) 209 ate wEU uence ad Printed in Japan ‘ADRSOS5ICO3. souap OuluseM yim g 9dhy Jo wesBoIp‘Printed in Japan ‘AQASOSS-JC03 CHAPTER 7 SERVICE STANDARD 1. Sorvica Standard Table (Engine) sense TA 2. Service Standard Table (Orive Unit) .suesnsenenenine 7Chapter 7 Service Standard Servi Engine L. Service Standard Table (Engine) SMID2TA & D36A (1) ava (Unit s me: Standard armension® [Stara 8] yo, oneal] item renee mentors reece |e] waar mt | Remorsa a ing f | = 370 +0.020 Reboring, if \ 4 sterceede | cvtinder tinge inside diameter] | 670 — — | 10 |thettme i | [Over ice ote3) | Gylinder inal ciometerreundneee) = = = L | 968.940 Piston outside diameter — | | 68.000 — 6.88 g s | peas 3 t 3 | clearance between 0 — $ | Gttsicein ond cv wm 7 0.18 assy 8 | liner insice ra, ai s { — Eee ee : aH | Piston pin boss hole diameter e | +0 oor | ot L | Piston pin outside dioreter i a0 Tet piston ring width ik - 18 cosets} oo | 38 | hat piston ring groove wiath ef i si & 85 / az piston ring wiath | 5 | gel SP a 18 Foomo0%0 | 012 | 3 | BE| 2 piston ring groove wicth E | 85 | oi ring wisn i 2 |fzp as a2 se 2 | 5* | oit ring groove wicth & [et anate2 piston ring | 00~0.35 by s 1 E | ovine 0.150.385 Tren an ouside ciomter ata 300 ae ~ 46 5288) ocamoos | 0.18 © crenk pin metal nse dometr ion © Tinos pn ousige dares oy T 1 1 ac om (52-0 oasso.oe | 0.1 5 Piston nin meta ise dlameter i] ee | [Feat awn Tare on ela See amare cocarrine | crenk. journal outside demeter oe ewes] oo | a0 | oorono.0ss | 0.18 | Crank main baring inside diame $0.00 40.08 © Grankahalt cde oop —— | bios : & | Detiestion (crank erm opening angi = = — Center deviation <0.03 0.05, i z L Intake vaive sinking 0.25 £0.1 “Os —— jy [Exhaust vole sinking “oso | #01 ~05 | ~ BT lmake/exhoust valve, | lntake (Tightening margin) 315) @.058~0. 058 oe & | seetvene Estowf Tightening margin) 26.9) ©.050—0.089 Printed in Japan 1 eee ‘AQASO55 ICOChapter 7 Service Standard 1. Service Standard Table (Engine) See cme nit mm) Slender’ amensions [SSeRSe ws tm amano [Sain [Me t=m*] wear mit] Rarerke FRigsgsaret|eseembing “He Stem diameter a =2ae | toto vive 7 sees | 0.12 Vahe guide s0.m : inside diamator $0.05 7.08 : oie z stom diameter F 6a 2 | Exhaust valve 07 0.085 | 9 025 ~0.085 O12 z Valve guide $0.08 a g inside diameter 0.008 2 Inteke | vawe nod thickness —— | on 08 exnoust aaa caeaie =B8 om a LSE naso.00 | ons Camshat boring inside diameter ¢ “o7 7 Inteke | 34.988 | 0.03 ater © | cam height Exhaust | 34,965 £0.03 — | For | sve | 2008 Compress Taree) 737 Gaim compresion) 18k | a {instestnt | ere tenth me) | % 2 Trelnaion 1 20 g L. & | iakeroxhaust vv arm shaft 3 73 2 ee See amma | ¢ (oti | ome | 08 5 | diemeter 0 16.03 & | Fuel valve arm ona cutie =O5% diameter 0.034 15.90 ei ho 018 Fuel valve arm insge dhametr . ee oe Pint in Japan ‘ROASOSS.1COSChapter 7 Service Standard 1. Service Standard Table (Engine) Spey poea (2) D368, Unit: mm Tonderd amienaions [SITE] max awa trem mentions are curing Weer limit | Remarks (game rentembing | Sen i 3 L 482 | | Reboring, if 2 fenceeae = | vince tine inside omer [| #8 — | ean |thelene 3 Le (Oversize of 2 s| ee | 08) © | Cylinder inside diameter roundness) 0.01 ee Pee 0.03 v | estan | 7808 ison outsidediomeer | m | vere) 20.06 | — | — | se | £ s) ¢eroso | =p ee 5 t 8 | ciaarancebatwoen piston | i { | S| aaesteanseytmaer fw] fm fom | — 8 | tne made oo zz aus He a + oa Piston pin boss hole diameter ie | i ; oe 2] wom | or ; Piston pin outside diemeter 7 3.0 | [tet mston rng wich 20 asso | 0 | — 3 Ete piston ring grave width | B | 85/2 piston ring wicth E | Ze) uineencnenis | ae aao~ooe | or | 2 | BE | ma piston rng groove with | ©) 88] oitring wiotn t © | 32 36 o.e2o~t.0%0 | 0.12 aaa § | O= | oit ring groove with | i end? piston rine [eon 7 12 3 [once 0150.85 Crank pin outside Gomer Lee ee 30 3 a SRE omc | 0.5 2 | Crank pin metal inside diameter 0,02 4.08 : : _ & | Piston pin outsice ameter a 2.00 3 Z a7 L208 | poco | on [je & | Piston pin metal inside diometer 0.025 Ga arsiieligm Between large end hole —— ‘end smail end hole : Ogee | .UTOlen | — Crank journl outside demote ar "9 - eo 22821 J poco | ots | & | cron bearing ne Gamer | yo08 [wo [ Cranksnatt side gap —_ | veo | 06 = | Deflection (crank arm opening angie) — ae Sel Center deviation $0.08 0 | : | [intake vive sinking oa [eer] es | 3 ‘Exhaust valve sinking 0.45 20.4 yor — | EF msaernaun ve, [sth Tighoning marin 3 | Banta J) & | Seat valve Esha] (Tiahtning meroin 33 | 0.057=0.18 I Pinte Japan ia "ADASOSS.JC03Chapter 7 Service Standard 1. Service Standard Table (Engine) |MID27A & D36A. Unit: mam fra dimensions [Satire ot Tyo, ogee ee sania res aracang (Mes OM] wor ime] Renee isons jfolaeaniay | e2eserbling Stem diameter i ‘" oa | | Intake valve ” como.06s | 0.12 g Verve guide = inside diameter | eed aa g Stem diemeter 6.02 2 | Exhaust valve | 7 x —— 2 jexunvose Fategmae—] *7 amis | ae gu Insignia | 2 Tstaxe i ] E | valve nead thickness +~— |] — _ an | os | Exhoust ‘Cemshatt outeide diameter 4a | +0 atso.ito | 0.16 | Camshet besring inside diameter [4.07 Jintao | arsma | 0.03 | 4183 | com height Jexhowt| ange | xo] — | — | ae | = —T Comprassive force | 237 T = 4 {at mm comprecsion)| 1.87af | I ae imaeternaus [Fras length cr 1 & | valve soring | Outer/inner 43.0780. | | | 0800 | 3 Inclination 18 z0 2 Taiakeromhaust vole orm shalt | i ie ; aes on Se on |S 3 | diameter | eae & [Fuel valve arm shalt outeide jometer_ 0.081 8 a2 [S80 onsso.ce | 0.18 [Fuel wei erm inside diameter | [eeee 2.08 7 Printed in Japan ‘AOASOS5.JCOBChapter 7 Service Standard 2. Service Standard Table (Drive Unit) SMID27A & D36A 2. Service Standard Table (Drive Unit) (0) vera (Unit: mm, Stendard dimensions | standerd cleerence | Mex. allowable Guring reassembling | cleorence Me tern 1 | Bala vin ain ad rr aa a 7 [Beka wean pan nd Tea ae | Forward ger bush nae omar 7] ees —{ ¢.010~0.082 os Proseler sett dameier 7 | cooling water pump key teknere Size 15 “E | Cooling weier pump outer plate — 1 oe 5 | eens : [sie 0s Coating wane per Ieper with ‘ ° ona oes Cooling wate pomp ian a — ment { | nivel brooke hote diameter om it diameter i‘ 7 | Pivot i ickress | Bush wel Tilt lock lover shett diameter y Bracket (shift) hole diameter = | aM ‘fone cantata iraecos cae ts Deere rowcone |S gases 11 [Pin (anit og) shat ameter jet oe Shift rod hole diameter et 10.1 pha eas ‘ROASOSS C03 78Chapter 7 Service Standard 2. Service Standard Table (Drive Unit) SMID2TA & D36A (2) 036A (nit: mm Eres Torsr srssedaavaseoe oneDa . em Nominal Dimensional | Suring reassembling Betatone | Bioaane 7 [Beciear between pinion andiorward | ren aaa a soot 7 | Beckanh batwennsision andere | a aia a oor +o Forward gear bush Inside donot 07 3 wo LB | 0.000 02 ous Proper shalt dlametor =o80 soar 7 4 | Geoting water pur Koy tikes «| ana Se | Salina water puro ote late 7 a See 08 Frekne : Cooling weir pump impale with wee | x0. 6 7 0~0.5 0.68 Cooling water pum iaert | soa ‘Sorc bracket hole ior we |e 7 | pi ahatt aiemeter vo | 20s ot eos Bush wal tikness 2 | te Tit ek lever sett dlometer a 8 eo LSB a opso. ae os ‘ewe bearing hoe giometer 3oe Bracket (2h) hole diameter a +O. 0 | Bush watt cknese ce | 2000 ots0.203 os Shit shat dimer v2 | ae 1D | Propeller shalt true caorence am oe 0 Dates (eit) hole demote BE Pate a 11 | Pin (shit roa) shatt diameter etn ona. Silt rod Wale aomeer ver) aot a Prine Japon ‘ACASO5S-JCO3CHAPTER 8 MAIN BOLT TIGHTENING TORQUE 1. Main Bolt Tightening Torque Printed in Japan ‘AQASOSS-JCO3Chapter 8 Main Bolt Tightening Torque 1. Main Bolt Tightening Torque sani bad 1. Main Bolt Tightening Torque 1-4 Engine Oencircled numbers show that engine parts differs for D27A and 026A. | Tightoned part Screw size | Width | heim] Remark | ightoned p: i L Tighteningforque| Remarks ca M 7X10) 12 2.2025 i ed Pelt M 9x10 3 45~5.0 maioxt 6 i 46~6.0 ®D | Metal cap bolt Mi2% 1.75 7 78085 | Main bearing case auxiliary bolt Mexia | 12 25-27 mies B eens @ | Flywheol tightening nut thts Bees

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