SEBM013001

DIESEL ENGINE

As a part of revision of this shop manual, special descriptions of the engines certified by the
EPA (Environmental Protection Agency) are added to the latter half of the manual (Chapter
20).
For the descriptions other than the above, see the first half, since they are the same as those
of the conventional engines.

© 2003
All Rights Reserved
Printed in Japan 06-03 (01)
00-1
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GENERAL

CONTENTS

1. GENERAL............................................................................................................ 1-1

2. TROUBLESHOOTING ......................................................................................... 2-1

3. INSPECTION AND ADJUSTMENT ..................................................................... 3-1

4. ENGINE BODY .................................................................................................... 4-1

5. LUBRICATION SYSTEM ..................................................................................... 5-1

6. COOLING SYSTEM ............................................................................................. 6-1

7. FUEL INJECTION PUMP/GOVERNOR .............................................................. 7-1

8. STARTING MOTOR............................................................................................. 8-1

9. ALTERNATOR..................................................................................................... 9-1

10. SPECIAL SERVICE TOOLS.............................................................................. 10-1

11. SERVICE STANDARDS .................................................................................... 11-1

20. EPA CERTIFIED ENGINE ................................................................................. 20-1

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 LIST OF REVISED PAGES

The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Page to be newly added Add

Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

or made additions.

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
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00-1 (1) 3-1 (1) 4-12 (1) 7-1 (1) 8-15 (1)
00-2 (1) 3-2 (1) 4-13 (1) 7-2 (1) 8-16 (1)
00-3 (1) 3-3 (1) 4-14 (1) 7-3 (1) 8-17 (1)
00-4 (1) 3-4 (1) 4-15 (1) 7-4 (1) 8-18 (1)
00-5 (1) 3-5 (1) 4-16 (1) 7-5 (1)
00-6 (1) 3-6 (1) 4-17 (1) 7-6 (1) 9-1 (1)
3-7 (1) 4-18 (1) 7-7 (1) 9-2 (1)
1-1 (1) 3-8 (1) 4-19 (1) 7-8 (1) 9-3 (1)
1-2 (1) 3-9 (1) 4-20 (1) 7-9 (1) 9-4 (1)
1-3 (1) 3-10 (1) 4-21 (1) 7-10 (1) 9-5 (1)
1-4 (1) 3-11 (1) 4-22 (1) 7-11 (1) 9-6 (1)
1-5 (1) 3-12 (1) 4-23 (1) 7-12 (1) 9-7 (1)
1-6 (1) 3-13 (1) 4-24 (1) 7-13 (1) 9-8 (1)
1-7 (1) 3-14 (1) 4-25 (1) 9-9 (1)
1-8 (1) 3-15 (1) 4-26 (1) 8-1 (1) 9-10 (1)
1-9 (1) 3-16 (1) 4-27 (1) 8-2 (1) 9-11 (1)
1-10 (1) 4-28 (1) 8-3 (1) 9-12 (1)
1-11 (1) 4-1 (1) 4-29 (1) 8-4 (1) 9-13 (1)
1-12 (1) 4-2 (1) 8-5 (1) 9-14 (1)
1-13 (1) 4-3 (1) 5-1 (1) 8-6 (1)
4-4 (1) 5-2 (1) 8-7 (1) 10-1 (1)
2-1 (1) 4-5 (1) 5-3 (1) 8-8 (1) 10-2 (1)
2-2 (1) 4-6 (1) 5-4 (1) 8-9 (1) 10-3 (1)
2-3 (1) 4-7 (1) 8-10 (1) 10-4 (1)
2-4 (1) 4-8 (1) 6-1 (1) 8-11 (1) 10-5 (1)
2-5 (1) 4-9 (1) 6-2 (1) 8-12 (1) 10-6 (1)
2-6 (1) 4-10 (1) 6-3 (1) 8-13 (1)
2-7 (1) 4-11 (1) 8-14 (1)

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LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
11-1 (1)
11-2 (1)
11-3 (1)
11-4 (1)
11-5 (1)
11-6 (1)
11-7 (1)
11-8 (1)
11-9 (1)

20-1 (1)
20-2 (1)

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 LIST OF REVISED PAGES

Applicable machine, Serial number

Engine output
Engine Machine model Machine Serial No. Remarks
(kW{HP}/rpm)

D20P-7 78604 and up 29.4 {39.4} / 2,450

D20P-7 62454 and up 29.4 {39.4} / 2,450

4D94E-1A D20PL-7 62454 and up 29.4 {39.4} / 2,450

D20PLL-7 62454 and up 29.4 {39.4} / 2,450

D20QG-7 62454 and up 29.4 {39.4} / 2,450

4D98E-1A D21A-7T 78604 and up 36.8 {49.3} / 2,450

Notice
Please update the part numbers and codes in this shop manual as follows.

[Method of updating]
Add YM in front of the part number and code.
(Note:This does not apply to all items. For details, see the Parts Book.)

(Example)
Update the part numbers and codes in this shop manual:172187-08520 o YM172187-08520

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LIST OF REVISED PAGES

Application Category

Application code Usage Eng. Rev. type. Revolution speed (rpm)

CL Generator drive Constant 1,500/1,800

VM General use Variable 2,000 – 2,500

+ For engine application category described in Chapter 1, Specifications.

Engine Nomenclature
4 D E—

Model

Cylinder bore (mm)

Diesel engine

Number of cylinders

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 1. GENERAL

1. GENERAL

1.1 Specifications......................................................................................................................................... 1- 2
1.2 Fuel oil, lubricating oil and cooling water ............................................................................................... 1- 4
1.3 Engine external views ............................................................................................................................ 1- 6
1.4 Structural description ............................................................................................................................. 1- 8
1.5 How to read this manual ...................................................................................................................... 1- 10
1.6 Precautions for service work................................................................................................................ 1- 12
1.7 Tightening torques for standard bolts and nuts ................................................................................... 1- 13

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1. GENERAL

1.1 Specifications
(1) 4D94E

Engine name — 4D94E

Engine specification class — VM

Type — Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber — Direct injection

Number of cylinders — 4

Cylinder bore x stroke mm x mm 94 x 100

Displacement l 2.776

Revolving speed rpm 2,000 2,200 2,400 2,500

Rated output kW 35.3 38.2 41.6 43.0
Output
{HP} {47.3} {51.2} {55.8} {57.7}

Fuel injection timing (FID, B.T.D.C.) deg 10 – 12

MPa 21.57 – 22.55

Fuel injection pressure
{kg/cm2} {220 – 230}

Ignition order — 1–3–4–2 (No.1 cylinder on flywheel side)

Power take off — Flywheel

Direction of rotation — Counterclockwise (viewed from flywheel)

Cooling system — Radiator

Lubrication system — Forced lubrication with trochoid pump

Starting system — Electric

Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2

Applicable fuel —
(cetane No. 45 min.)

Applicable lubricant — API grade class CC or higher

Battery capacity V-AH 12–64 (5HR) or above

Lubricant capacity Total l 10.2

(oil pan) Effective l 4.5

Cooling water capacity (engine only) l 4.2

Overall length mm 720

Engine dimensions Overall width mm 508

Overall height mm 689

Dry engine weight kg 223

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 1. GENERAL

(2) 4D98E

Engine name — 4D98E

Engine specification class — VM

Type — Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber — Direct injection

Number of cylinders — 4

Cylinder bore x stroke mm x mm 98 x 110

Displacement l 3.319

Revolving speed rpm 2,000 2,200 2,400 2,500

Rated output kW 41.9 45.6 49.3 51.1
Output
{HP} {56.2} {61.2} {66.1} {68.5}

Fuel injection timing (FID, B.T.D.C) deg 10 – 12

MPa 21.57 – 22.55

Fuel injection pressure
{kg/cm2} {220 – 230}

Ignition order — 1–3–4–2 (No.1 cylinder on flywheel side)

Power take off — Flywheel

Direction of rotation — Counterclockwise (viewed from flywheel)

Cooling system — Radiator

Lubrication system — Forced lubrication with trochoid pump

Starting system — Electric

Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2

Applicable fuel —
(cetane No. 45 min.)

Applicable lubricant — API grade class CC or higher

Battery capacity V-AH 12–64 (5HR) or above

Lubricant capacity Total l 10.2

(oil pan) Effective l 4.5

Cooling water capacity (engine only) l 4.2

Overall length mm 720

Engine dimensions Overall width mm 508

Overall height mm 689

Dry engine weight kg 223

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1. GENERAL

1.2 Fuel oil, lubricating oil and cooling water

(1) Fuel oil
k Use of other than the specified fuel oil may fail to obtain the full engine performance or cause parts failures.

• Applicable fuel
Always use diesel gas oil ISO 8217DMA, BS 2869A1 or A2 (cetane No. 45 min.) that is most suitable for
desired engine performance.

(2) Lubricating oil

k Use of other than the specified lubricating oil may cause inner parts seizure or early wear, leading to
shortening of the engine service life.

• Applicable lubricating oil:

API grade CC class or higher
If the engine oil sold on the market is to be used,
always select class CD or CC (API classifica-
tion.)
Select the viscosity number according to the
ambient temperature by referring to the table
below.

• Handling of lubricating oil

1) Carefully store and handle the oil so as to
prevent dust or dirt entrance. When
supplying the oil, pay careful attention and
clean around the filler port.
2) Do not use mixture of different types of oil
as it may degrade the lubricating
performance.

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 1. GENERAL

(3) Cooling water

Use clean drinkable water (tap water or rainwater) as the cooling water.

k Always add antirust or antifreeze in the cooling water.

Especially in cold weather, be sure to add antifreeze to prevent freezing. Since scale or rust will be generated
in the water piping when only clear water is used, the cooling performance is worsened. In a cold weather,
the cooling water may be expanded by freezing to cause damage to the cooling system parts.

1) Rust preventive agent

Be sure to add the rust preventive agent to the cooling water. However, do not use it in cold weather
because freezing will occur.

When you use a rust preventive agent sold on the market, be sure to follow the mixing rate designated
by the manufacturer.
Replace the rust preventive agent once a year.

2) Antifreeze

k Excessive addition of antifreeze will worsen engine cooling.

Always observe the mixing rate specified by the manufacturer for each ambient temperature.
• In cold weather, be sure to add the antifreeze to prevent freezing.
If you use antifreeze, addition of the rust preventive agent is unnecessary. Antifreeze can be used
throughout the year. The mixing rate should be between 30% and 55%.

Lowest atmosperic temperature

–15 or above –20 –25
(°C)

Mixing rate (%) 30 35 40

• When you use an antifreeze sold on the market, be sure to follow the mixing rate designated by the
manufacturer.
Replace the antifreeze once a year.

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1. GENERAL

1.3 Engine external views

8
6 7
2 4 12 14
10
3 5
9 11 15
13

16

21 17
20 19 18 YE0351

1) Starting motor 12) Fuel injection pump

2) Exhaust manifold 13) Cooling water outlet
3) Bonnet 14) Cooling water inlet
4) Cylinder head 15) Radiator fan
5) Intake manifold 16) Oil filler port
6) Fuel injection nozzle 17) Fuel feed pump
7) Gear case 18) Oil strainer
8) Gear case cover 19) Dipstick
9) Fuel filter 20) Oil pan
10) Engine stop motor 21) Flywheel housing
11) Governor

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 1. GENERAL

22 23

YE0352

22) Cooling water pump

23) Alternator

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1. GENERAL

1.4 Structural description

13 2

12 4

11 5

10

9
6

7
8 YE0353

1) Rocker arm housing 8) Engine oil filter (oil cooler: option)

2) Rocker arm 9) Fuel injection pump
3) Exhaust manifold 10) Piston
4) Tappet 11) Cylinder block
5) Camshaft 12) Intake manifold
6) Engine oil pan 13) Fuel injection nozzle
7) Connecting rod cap bolt

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 1. GENERAL

15
16
17
14

18

21 20 19
YE0354

14) Water pump 18) Crankshaft

15) Thermostat 19) Flywheel housing
16) Cylinder head gasket 20) Gear case (equipped with oil pump)
17) Cylinder head 21) Gear

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1. GENERAL

1.5 How to read this manual

(1) Range of Operation Explanation
This manual explains the troubleshooting, installation/removal, replacement, disassembly/reassembly,
inspection, adjustment and adjusting operation procedures for the 4D94/98 engine.
Refer to the manufacturer’s manual for each of the fuel injection pump, governor, starting motor and alterna-
tor except for their installation.

(2) How to Read the Explanations

(2-1) An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section
as required for easy understanding of the mounted states of the components.
(2-2) For the removal/installation of each part, the procedure is shown with the procedural step No. in the
illustration.
(2-3) Precautions and key points for disassembly and reassembly of parts are described as Points. In the
explanation for each point, detailed operation method, information, standard and precautions are
described.

Description Example

• Illustration

YE0355

a The job contents are described in the disassembly procedure for Nos. not shown in the illustration.

• Disassembly procedure • Operation Points

(1) Follow steps (1) to (12) of the cylinder head Disassemble: Service point for removal
disassembly procedure. Reassemble: Service point for installation
(2) Remove the cooling water pump. Disassemble-Reassemble: Service point
(3) Remove the crankshaft pulley. (Point 1) required in both removal and installation.

Operation point to be explained on a later page.

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 1. GENERAL

• Contents omitted in this manual

Though the following jobs are omitted in the explanation in this manual, they shold be conducted in
actual work:
(1) Jacking up and lifting
(2) Cleaning and washing of removed parts as required
(3) Visual inspection

(3) Definition of Terms

k Instruction whose negligence is very likely to cause an accident. Always observe it.
Standard: Allowable range for inspection and adjustment.
Limit: The maximum or minimum value that must be satisfied during inspection or adjustment.

(4) Abbreviations

Abbreviation Meaning Abbreviation Meaning

Ass’y assembly T.D.C top dead center

Sub-Ass’y sub-assembly B.D.C bottom dead center

A.T.D.C. after top dead center OS oversize

B.T.D.C. before top dead center US undersize

STD Standard rpm revolutions per minute

IN Intake HP output (horsepower)

EX Exhaust 3 Bolt/nut tightening torque

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1. GENERAL

1.6 Precautions for service work

(1) Precautions for Safety
Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.

(2) Preparation for Service Work

Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history
of the engine.
(2-1) Preceding service date
(2-2) Period/operation hours after preceding service
(2-3) Problems and actions in preceding service
(2-4) Replacement parts expected to be required for service
(2-5) Recording form/check sheet required for service

(3) Preparation before Disassembly

(3-1) Prepare general tools, special service tools, measuring instruments, oil, grease, non-reusable parts,
and parts expected to be required for replacement.
(3-2) When disassembling complicated portions, put matchmarks and other marks at places not adversely
affecting the function for easy reassembly.

(4) Precautions in Disassembly

(4-1) Each time a parts is removed, check the part installed state, deformation, damage, roughening,
surface defect, etc.
(4-2) Arrange the removed parts orderly with clear distinction between those to be replaced and those to be
used again.
(4-3) Parts to be used again shall be washed and cleaned sufficiently.
(4-4) Select especially clean locations and use clean tools for disassembly of hydraulic units such as the
fuel injection pump.

(5) Precautions for Inspection and Measurement

(5-1) Inspect and measure parts to be used again as required to determine whether they are reusable or
not.

(6) Precautions for Reassembly

(6-1) Reassemble correct parts in correct order according to the specified standards (tightening torques,
and adjustment standards). Apply oil to important bolts and nuts before tightening when specified.
(6-2) Always use genuine parts for replacement.
(6-3) Always use new oil seals, O-rings, packings and cotter pins.
(6-4) Apply sealant to packings depending on the place where they are used. Apply oil or grease to sliding
contact portions, and apply grease to oil seal lips.

(7) Precautions for Adjustment and Check

(7-1) Use measuring instruments for adjustment to the specified service standards.

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 1. GENERAL

1.7 Tightening torques for standard bolts and nuts

(Lubricating oil not applied)
(Unit: Nm {kgm})

Nominal thread
Item Tightening torque Remarks
diameter x pitch

M6 x 1 9.8 – 11.8 {1.0 – 1.2}
M8 x 1.25 22.5 – 28.4 {2.3 – 2.9}
Hexagon bolt (7T)/nut
M10 x 1.5 44.1 – 53.9 {4.5 – 5.5}
1) Use 80% of the value at left when
the tightening side is aluminum.
2) Use 60% of the value at left for 4T
bolts and lock nuts.

M12 x 1.75 78.4 – 98 {8.0 – 10}

1/8 9.8 {1.0}

1/4 19.6 {2.0}
PT plug
3/8 29.4 {3.0}

1/2 58.8 {6.0}

M8 12.7 – 16.7 {1.3 – 1.7}

M12 24.5 – 34.3 {2.5 – 3.5}

Pipe joint bolt
M14 39.2 – 49 {4.0 – 5.0}

M16 49 – 58.8 {5.0 – 6.0}

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 2. TROUBLESHOOTING

2. TROUBLESHOOTING

2.1 Quick reference table for troubleshooting .............................................................................................. 2- 2

2.2 Troubleshooting by measuring compression pressure .......................................................................... 2- 6

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2. TROUBLESHOOTING

2.1 Quick reference table for troubleshooting

The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs,
take corrective action before it developes into a serious problem so as not to shorten the engine service life.

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 2. TROUBLESHOOTING

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2. TROUBLESHOOTING

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 2. TROUBLESHOOTING

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2. TROUBLESHOOTING

2.2 Troubleshooting by measuring compression pressure

Compression pressure drop is one of major causes of increasing blowby gas (lubricating oil contamination or
increased lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pressure
is affected by the following factors:
1. Degree of clearance between piston and cylinder
2. Degree of clearance at intake/exhaust valve seat
3. Gas leak from nozzle gasket or cylinder head gasket
In other words, the pressure drops due to increased parts wear and reduced durability resulting from long use of
the engine.
A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner
element or worn or broken piston ring. Measure the compression pressure to diagnose presence of any abnor-
mality in the engine.

1. Compression pressure measurement method

(1) After warming up the engine, remove the
fuel injection pump and nozzles from the
cylinder to be measured.
(2) Crank the engine before installing the
compression gauge adapter. 1
a1 Perform cranking with the regulator han-
dle at the stop position (no injection
state).
a2 See 10.2-18 in Chapter 10 for the com-
pression gauge adapter.
(3) Install the compression gauge and compression
gauge adapter at the cylinder to be measured. YE0356

a Never forget to install a gasket at the tip

end of the adapter. Measuring the compression pressure
(4) With the engine set to the same state as in
(2) a1, crank the engine by the starter 1) Compression gauge
motor until the compression gauge reading
is stabilized.

2. Standard compression pressure

[Engine compression pressure list (reference value)]

Compression pressure (MPa {kg/cm2}) at 250 rpm Dispersion among cylinders

Engine model
Standard Limit (MPa {kg/cm2})

4D94E 3.4 ± 0.1 {35 ± 1} 2.6 {27} 0.2 – 0.3 {2 – 3}

4D98E 3.4 ± 0.1 {35 ± 1} 2.6 {27} 0.2 – 0.3 {2 – 3}

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 2. TROUBLESHOOTING

3. Engine speed and compression pressure (reference)

4. Measured value and troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.

No. Item Cause Corrective action

1 • Air cleaner element
2 • Valve clearance
• Clogged element
• Clean the element.
• Broken element
• Replace the element
• Defect at element seal portion
• Adjust the valve clearance.
• Excessive or no clearance
(See 3.5 in Chapter 3.)

• Adjust the valve clearance.

3 • Valve timing • Incorrect valve clearance
(See 3.5 in Chapter 3.)

• Replace the gasket.

• Retighten the cylinder head
4 • Cylinder head gasket • Gas leak from gasket
bolts to the specified torque.
(See 4.2 (2) B in Chapter 4.)

• Lap the valve seat.

• Gas leak due to worn valve seat
• Intake/exhaust valve (See 4.2 (6) in Chapter 4.)
5 or foreign matter trapping
• Valve seat • Replace the intake/exhaust
• Sticking valve
valve.
• Perform honing and use an
• Piston
• Gas leak due to scratching or oversized part.
6 • Piston ring
wear (See 4.4 (5)-(5-1), (5-4) and (6)
• Cylinder
in Chapter 4.)

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 3. INSPECTION AND ADJUSTMENT

3. INSPECTION AND ADJUSTMENT

3.1 Oil inspection ......................................................................................................................................... 3- 2

3.2 Cooling water inspection........................................................................................................................ 3- 2
3.3 Inspecting water leak from cooling water system and radiator .............................................................. 3- 2
3.4 Fan belt tension inspection and adjustment .......................................................................................... 3- 3
3.5 Adjustment the valve clearance............................................................................................................. 3- 4
3.6 Inspecting the fuel injection nozzle injection pressure and spray pattern .............................................. 3- 5
3.7 Fuel injection timing inspection and adjustment .................................................................................... 3- 8
3.8 Adjusting the no-load maximum (or minimum) revolutions .................................................................... 3- 9
3.9 Sensor inspection ................................................................................................................................ 3- 10
3.10 Battery inspection ................................................................................................................................ 3- 11
3.11 Adjusting operation .............................................................................................................................. 3- 13
3.12 Long storage........................................................................................................................................ 3- 14
3.13 Periodic maintenance schedule........................................................................................................... 3- 15

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3. INSPECTION AND ADJUSTMENT

3.1 Oil inspection

• Standard
The level shall be between the upper and lower
limit lines on the dipstick.

Total volume 10.2 l

Effective volume 4.5 l

1 2

k The oil should not be overfilled to exceed

the upper limit line. Otherwise, oil may jet
out from the breather or the engine may 3
YE0358
become faulty.
(1) The oil shall not be contaminated heavily
and have appropriate viscosity. No cooling
water or diesel gas oil shall be mixed.
(2) Insert the dipstick fully and check the oil
level.

3.2 Cooling water inspection 4

5
• Standard
Engine: The radiator shall be filled up.
Sub-tank: The water level shall be between the 6
upper and lower limit lines. YE0359

Engine 4.2 l
Capacity 1) Tighten 4) Upper limit
Sub-tank Approx. 0.8 l
2) Loosen 5) Lower limit
3) Radiator cap 6) Sub-tank

(1) The cooling water shall be checked when

the engine is cold.
(2) If the water level is normal in the sub-tank
but low in the radiator, check loosened
clamping of the rubber hose between the
radiator and sub-tank or tear in the hose.

3.3 Inspecting water leak from cooling water system and radiator
1. Water leak check in cooling water system
(1) Fill cooling water to the normal level in the
radiator, and install the cap tester on the
radiator.
(2) Operate the manual pump to set the
pressure to 90 ± 15 Pa {0.9 ± 0.15 kg/cm2}. If
the cap tester pressure gauge reading drops
then, water is leaking from the cooling water
system. Check the water leaking point.

1
1) Cap tester
YE0360

Water leak check in cooling water system

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 3. INSPECTION AND ADJUSTMENT

2. Radiator cap inspection

Install the radiator cap on the cap tester. Set the
tester pressure to 90 ± 15 Pa {0.9 ± 0.15 kg/cm2}
and see that the cap is opened. If the cap does
not open, replace the cap since it is abnormal.

2) Radiator cap
2
YE0361

Radiator cap inspection

3.4 Fan belt tension inspection and adjustment

Standard: 10 – 15 mm/98N {10kg} 98N {10kg}

(7 – 9 mm in initial state)

10~15mm
Push the center of the V belt between the alter-
nator and cooling water pump with a finger. The
V-belt tension is normal if the deflection is 10 to
15 mm. If not, adjust the V-belt tension by the 2
alternator adjuster. 1

3
1) Cooling water pump
YE0362
2) Alternator
3) Crankshaft pulley V-belt tension
4) Adjuster
5
5) Bar (for adjusting
V-belt tension)
6) Alternator 4

6
YE0363

Tension adjustment

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3. INSPECTION AND ADJUSTMENT

3.5 Adjusting the valve clearance

Standard: 0.15 – 0.25 mm

Make adjustment when the engine is cold.

(1) Set the piston in the cylinder to be adjusted

to the compression T.D.C. (Position where
both intake and exhaust valves are closed)
(2) Loosen the lock nut and adjusting screw,
and check the valve cap for any inclination,
entrapped dirt or wear.
(3) Insert a 0.2 mm thickness gauge between YE0364
the rocker arm and valve cap, and tighten
the adjusting screw to adjust the valve Valve clearance adjustment
clearance.
(4) Apply oil to the contact between the 2
adjusting screw and push rod.
1
3
1) Valve clearance
2) Adjusting screw
3) Lock nut
4) Valve cap
5) Normal
6) Abnormal
YE0365
Valve clearance

a If the valve cap head portion is worn,

replace the cap with a new one.
a See that each valve cap is fully covering
the intake/exhaust valve head.

5 6
YE0366

3-4 94E-98E SERIES

(1)
 3. INSPECTION AND ADJUSTMENT

3.6 Inspecting the fuel injection nozzle injection pressure and

spray pattern
k Wear protective glasses when testing injection from the fuel injection nozzle. Never approach the injection
nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or
injury if coming into careless contact with it.

1. Fuel injection pressure measurement

MPa 21.57 – 22.55

Standard
{kg/cm2} {220 – 230}

a Remove carbon deposit at the nozzle hole thoroughly before measurement.

(1) Connect the fuel injection nozzle to the high

pressure pipe of the nozzle tester.
(2) Operate the nozzle tester lever slowly and
read the pressure at the moment when the
fuel injection from the nozzle starts.
(3) If the measured injection pressure is lower 2
than the standard level, replace the
pressure adjusting shim with a thicker one.

1
1) Fuel injection
nozzle
YE0367
2) Nozzle tester
Fuel injection pressure measurement
with nozzle tester

Type of pressure adjusting shim thickness (mm) Fuel injection pressure adjustment

The fuel injection pressure is increased by approx. 1.9 MPa

0.13, 0.15, 0.18, 0.4, 0.5, 0.8 {19 kg/cm2} when the adjusting shim thickness is increased
by 0.1 mm.

94E-98E SERIES 3-5

(1)
3. INSPECTION AND ADJUSTMENT

[Reference: Fuel injection nozzle structure]

3) Fuel return pipe joint 3
4) Nozzle holder
5) Pressure adjusting
shim
6) Nozzle spring
7) Nozzle spring seat 4
8) Valve stop spacer
9) Nozzle valve
10) Nozzle body
11) Nozzle 5
12) Nozzle case nut
13) Dowel pin 6

7
8

9
13
11
10

12

YE0368

2. Spray pattern inspection

After adjustment to the specified valve opening
pressure, use a nozzle tester and check the
spray pattern and seat oil-tightness.

(1) Seat oil-tightness check

• After injecting a few times, increase the
pressure gradually. Hold the pressure
for about 5 seconds at a little before the
valve opening pressure of 2.0 MPa {20
kg/cm2}, and check to see that oil does
not drip from the tip end of the nozzle. YE0369

• If extreme oil leak from the overflow joint

exists during injection by the nozzle Normal (Uniform spray pattern from each nozzle)
tester, check after retightening. If much
o il i s le a ki n g, re pl a c e t he no z zl e
assembly.

3-6 94E-98E SERIES

(1)
 3. INSPECTION AND ADJUSTMENT

(2) Spray and injection states

• Operate the nozzle tester level at a rate
of once or twice a second and check no
abnormal injection.
• If normal injection as shown below
cannot be obtained, replace the fuel
injection nozzle.
• No extreme difference in angle ( )
• No extreme injection angle difference
( )
• Finely atomized spray
• Excellent spray departure YE0370

Abnormal
Extreme difference in angle ( )
Extremely different injection angle ( )
Non-atomized spray
Stagnant spray

3. Nozzle valve sliding test

Wash the nozzle valve in clean fuel oil. Place
the nozzle body vertically and insert the nozzle
into the body to about 1/3 of its length. The valve
is normal if it smoothly falls by its own weight
into the body. In case of a new nozzle, remove
the seal peel, and immerse it in clean diesel oil
or the like to clean the inner and outer surfaces
and to thoroughly remove rust-preventive oil
before using the nozzle. Note that a new nozzle
is coated with rust-preventive oil and is pasted
with the seal peel to shut off outer air. YE0371

Nozzle valve sliding check by gravity

4. Nozzle punch mark

Design code
Size : size P
: size S
Injection angle
Nozzle insertion angle
Code A: angled
No code: no angle

Type: DLL (semi-long type)

YANMAR

Punch mark
YE0567

94E-98E SERIES 3-7

(1)
3. INSPECTION AND ADJUSTMENT

3.7 Fuel injection timing inspection and adjustment

1) Turn the engine by using the crankshaft pulley. Inspect the fuel injection timing of No.1 cylinder by
means of the delivery valve spring holder of the fuel injection pump (cylinders numbered No. 1, 2, 3 and
4 from the flywheel side).

2) Rotate the crankshaft clockwise as seen from the pulley side. Since the oil level at the tip end of the
delivery valve spring holder rises, stop rotation as soon as it rises.

3) Check the crankshaft TOP mark and timing

scale position.

Standard: B.T.D.C. 10 – 12° (FID)

a. Crankshaft pulley
b. TOP mark
c. Fuel injection pump
mounting nut

c YE0373

4) If the fuel injection timing does not satisfy the standard, adjust it by tilting the fuel injection pump body
toward or away from the engine after loosening the fuel injection pump mounting nut. If the timing is
delayed, tilt the pump body away from the engine.
If the timing is too early, tilt the pump body toward the engine.

3-8 94E-98E SERIES

(1)
 3. INSPECTION AND ADJUSTMENT

3.8 Adjusting the no-load maximum (or minimum) revolutions

(1) After warming the engine up, gradually raise
the speed and set it at the no-load maximum
revolution. 1 2
(2) If the no-load maximum revolution is outside
the standard range, adjust it by turning the
no-load maximum revolution adjusting bolt.
(3) Then set the no-load minimum revolution by
adjusting the no-load minimum revolution
adjusting bolt.
3 4 3 4

• Standards

(Unit: rpm)

No-load No-load
Rating maximum minimum
revolution revolution YE0374

2,000 2,155 – 2205 800 or less

1) No-load maximum revolution adjusting bolt
2,200 2,373 – 2423 800 or less 2) No-load minimum revolution adjusting bolt
2,400 2,567 – 2617 800 or less 3) Decrease
4) Increase
2,500 2,675 – 2725 800 or less

94E-98E SERIES 3-9

(1)
3. INSPECTION AND ADJUSTMENT

3.9 Sensor inspection

1. Thermostat and Thermal Switch Inspection
(1) Thermostat
Place the thermostat in a container filled 1
with water. Heat it while measuring the
water temperature, and see that the thermo-
stat is actuated at 69.5 – 72.5°C.

2
1) Thermometer
2) Thermostat
3) To radiator
4) Cover YE0375

5) Thermostat
6) Thermoswitch 3

(2) Thermoswitch 4
Place the thermoswitch in a container filled
with antifreeze or oil. Heat it while measur-
ing the fluid temperature. The switch is nor- 5
mal if the voltammeter shows continuity
when the fluid temperature is 107 – 113°C.

YE0376

2. Oil pressure switch 7

Disconnect the connector from the oil pressure
switch. Keep the voltammeter probes in contact
with the switch terminal and cylinder block while
operating the engine. It is abnormal if circuit is
closed.
8

7) Thermometer
8) Tester probes
9) Tester probes
10) Cylinder block YE0377
(flywheel side)
10
9

YE0378

Continuity test

3-10 94E-98E SERIES

(1)
 3. INSPECTION AND ADJUSTMENT

3.10 Battery inspection

1. Battery structure
2 3

1) Battery case 4
2) Terminal
3) Cap
4) Cover 5
5) Cathode plate 6
6) Separator 1 7
7) Glass mat
8) Anode plate
8

YE0379

2. Battery inspection
(1) Electrolyte level
Add distilled water to the upper limit if the
level is low.

9) Upper limit
10) Lower limit 9
10
11) OK
12) Too low
13) Excessive
11 12 13
14) Electrolyte level
15) Battery tester

14
YE0380

(2) Battery charge

Use a battery tester or hydrometer and
check the battery condition. If the battery is
discharged, recharge it.
• Measurement with a battery tester
When checking the battery with the bat-
tery tester, connect the red clip of the
tester to the battery positive (+) terminal
and black clip to the battery negative (–)
terminal by pinching them securely, and
judge the battery charge level from the
indicator position.
Green zone: Normal
Yellow zone: Slightly discharged
15
Red zone: Defective or much
YE0381
discharged
Battery charge measurement with battery tester

94E-98E SERIES 3-11

(1)
3. INSPECTION AND ADJUSTMENT

• Measurement with hydrometer

When using a hydrometer, the mea-
sured specific gravity must be corrected
according to the temperature at the time
of measurement. The specific gravity of
battery electrolyte is defined with 20°C
as the standard. Since the specific grav-
ity increases or decreases by 0.0007 1
when the temperature varies by 1°C,
correct the value according to the equa-
tion below.

S20 = St + 0.007 (t – 20)

Electrolyte temperature
at measurement

Specific gravity at measurement YE0382

Battery charge measurement with a hydrometer

Converted specific gravity at 20°C

2

Specific gravity and remaining 3

battery charge

Discharged
Specific Remaining
quantity of 4
gravity charge
electricity
(20°C) (%)
(%)
1.260 0 100 YE0383

1.210 25 75
Hydrometer structure
1.160 50 50
1) Float 3) Glass tube
1.110 75 25 2) Rubber bulb 4) Float
1.060 100 0

(3) Terminals
Clean if corroded or soiled.
(4) Mounting bracket
Repair or replace it if corroded.
Retighten if loosened.
(5) Battery appearance
Replace the battery if cracked or deformed.
Clean with fresh water if contaminated.

YE0384

How to read hydrometer

3-12 94E-98E SERIES

(1)
 3. INSPECTION AND ADJUSTMENT

3.11 Adjusting operation

Perform adjusting operation as follows after the maintenance job:

(1) Supply the fuel oil, lubricating oil and cooling water.
a Check the levels of the lubricating oil and cooling water again after test running (for about 5 minutes)
and add as required.

(2) Start the engine, and carry out idling at a low revolution (700 to 900 rpm) for a few minutes.

(3) Run in the engine for about five minutes at the rated revolution (no-load). Check any water, fuel or oil leak
and existence of abnormal vibration or noise. Also check the oil pressure, cooling water temperature and
exhaust gas color.

(4) Adjust the no-load minimum and maximum revolutions according to the specifications.

(5) Perform loaded operation as required.

94E-98E SERIES 3-13

(1)
3. INSPECTION AND ADJUSTMENT

3.12 Long storage

Observe the following instructions when the engine is to be stored for a long period without operation:

1. Always drain cooling water in a cold season or before a long storage. (This is unnecessary when antifreeze
is used.)
k Negligence of water draining will cause the cooling water remaining inside the engine to be frozen and
expanded to damage the engine parts.
Water draining procedure
(1) Remove the radiator cap.
(2) Loosen the water draining valve under the radiator to drain water from the inside.
(3) Loosen the drain valve on the side surface of the cylinder to drain water from the inside.
(4) After draining water, tighten the radiator cap and drain plug and valves.

2. Remove the mud, dust and oil deposit and clean the outside.

3. Perform the nearest periodic inspection before the storage.

4. Drain or fill the fuel oil fully to prevent condensation in the fuel tank.

5. Disconnect the battery cable from the battery negative (–) terminal.

6. Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from depositing
or entrance.

7. Select a well-ventilated location without moisture and dust for storage.

8. Perform recharging once a month during storage to compensate for self-discharge.

3-14 94E-98E SERIES

(1)
 3. INSPECTION AND ADJUSTMENT

3.13 Periodic maintenance schedule

The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities
of the fuel and lubricating oils used and handling status. General rules are described here.

k Make a periodic inspection plan according to the state of use. Perform periodic inspection accurately so that
inspection will not be skipped. If periodic inspection is neglected, failures may occur or durability may be lost.
Inspection and maintenance after 1000 hours require expertise and skill, so consult our dealer or distributor.

Every 3 Every 6 Every year

Every month
month or month or or
Part Item Daily or
Every 200 Every 400 Every 1000
Every 50 hrs.
hrs. hrs. hrs.

Check the fuel level and refill before

operation

Drain the fuel tank once a

month

Clean the fuel filter

Replace the fuel filter element

Fuel oil
Drain the water separator if appli-
system
cable

Check for fuel oil leakage after

operation

Fuel injection Check the injection

nozzle condition

Check the fuel injection timing

Check the fuel injection pump

Check the lubricating oil level in

before
the oil pan and refill
operation

Replace the lubricating oil 2nd time and

Lubricating 1st time
thereafter
oil
system Replace the lubricating oil filter
2nd time and
element 1st time
thereafter

Check for lubricating oil leakage after

operation

94E-98E SERIES 3-15

(1)
3. INSPECTION AND ADJUSTMENT

Every 3 Every 6 Every year

Every month
month or month or or
Part Item Daily or
Every 200 Every 400 Every 1000
Every 50 hrs.
hrs. hrs. hrs.

Check the cooling water level and

before
refill
operation

Clean the cooling water passage

Replace the cooling water

once a year

Check the cooling water leakage after

Cooling operation
water
system Check for clogging before
Radiator fin operation

Clean the fin

Adjust the fan belt tension 2nd time and

1st time
thereafter

Check the fan belt before

operation

Air Check the air cleaner element

intake
system Replace the air cleaner element

Check the battery electrolyte level

before
and refill
operation
Electric
system
when the
Check the warning lamps
engine is
started

Engine Adjusting the intake and exhaust

body valve clearance

Item marked " " should be serviced by an authorized dealer, unless the owner has proficient mechanical ability
and the proper tools.

3-16 94E-98E SERIES

(1)
 4. ENGINE BODY

4. ENGINE BODY

4.1 Introduction ............................................................................................................................................. 4-2

4.2 Cylinder head.......................................................................................................................................... 4-3
4.3 Gear train and camshaft ....................................................................................................................... 4-12
4.4 Cylinder block ....................................................................................................................................... 4-17

94E-98E SERIES 4-1

(1)
4. ENGINE BODY

4.1 Introduction
Make preparation as follows before starting engine inspection and service:

(1) Fix the engine on a horizontal base.

k Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.

(2) Remove the cooling water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven
machine and engine, and drain cooling water, lubricating oil and fuel.

(3) Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so
as not to let any foreign matter enter the engine.

k Always wear glasses or other protectors when using compressed air or steam to prevent any foreign
matter from getting in the eyes.

a Any part which is found defective as a result of inspection or any part whose measured value does not
satisfy the standard or limit shall be replaced.
a Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state
of use should be replaced even when the measured value then satisfies the standard or limit.

4-2 94E-98E SERIES

(1)
 4. ENGINE BODY

4.2 Cylinder head

(1) Components

YE0385

(2) Disassembly procedure:

Disassemble in the order of the numbers shown in the illustration.
Remove the alternator ass’y. (Point 1)
Remove the fan, pulley and V belt.
Remove the thermostat case. (Point 2)
Remove the fuel filter and fuel oil piping (Point 3)
Remove the oil level gauge ass’y.
Remove the oil filter. (Point 4)
Remove the fuel injection pipes. (Point 5)
Remove the intake manifold ass’y.
Remove the exhaust manifold ass’y.
Remove the bonnet ass’y.
Remove the rocker shaft ass’y, push rods and valve caps. (Point 6)
Remove the cylinder head ass’y and head gasket. (Point 7)
Remove the fuel injection nozzles and fuel return pipe. (Point 8)
Remove the intake/exhaust valves, valve stem seals and valve springs. (Point 9)
Remove the rocker arms from the rocker arm shaft.

94E-98E SERIES 4-3

(1)
4. ENGINE BODY

(3) Reassembly procedure:

Reverse order of the disassembly procedure.

(4) Servicing points

Point 1
Disassemble:
• Loosen the mounting bolt while supporting
the alternator.
2
k Do not tilt the alternator toward the cylinder 1
block in a haste since it may damage the
alternator or pinch a finger.
3
Reassemble:
YE0386
• The belt deflection shall be 10 – 15 mm
V-belt tension
(7 – 9 mm for a new belt).
Reassemble:
• Replace the belt with a new one if cracked, 5
worn or damaged.
• Carefully prevent the belt from being 4
smeared with oil or grease.

1) Cooling water pump

2) Alternator
3) Crankshaft pulley
4) Adjuster
5) Bar (for adjusting 6
V-belt tension)
YE0387
6) Alternator Tension Adjustment

Point 2
Reassemble:
• Check the thermostat function. (See 3.9 in Chapter 3 for the check procedure.)

Point 3
Reassemble:
• Replace the fuel filter element with a new one.
Disassemble:
• Cover the fuel pipe opening with tape to prevent intrusion of foreign matters.

Point 4
Reassemble:
• Replace the oil filter with a new one.
• After fully tightening the filter manually, retighten it with a filter wrench (see 10.1-6 in Chapter 10) by 3/4
turn.

Point 5
Disassemble:
• Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of
foreign matters.

4-4 94E-98E SERIES

(1)
 4. ENGINE BODY

Point 6
Disassemble:
• Keep the removed push rods by attaching tags showing corresponding cylinder Nos.
Reassemble:
• Always apply oil to the contact portions of the push rods and clearance adjusting screws.

Point 7
Disassemble:
• Loosen the cylinder head bolts in two steps
1
in the illustrated order.
• Place the cylinder head ass’y on a paper
board to prevent the combustion face from
YE0388
any damage.
Reassemble: Disassembly
• Remove the head gasket with a new one. Head bolt disassembly order
• Uniformly tighten the head bolts manually
after applying oil on the threaded and seat
portions.
• They shall be tightened in two steps in the 1
reverse of the order for disassembly.

YE0389
1) Fan side Assembly

3
Head bolt tightening order

First step: 49 – 58.8 Nm {5 – 6 kgm}

Second step: 102.9 – 112.7 Nm {10.5 – 11.5 kgm}

Point 8
Disassemble:
• Carefully remove the fuel injection nozzle so as not to leave the tip end protector from being left inside
the cylinder.
Reassemble:
• Replace the fuel injection nozzle protector with a new one.

Point 9
Disassemble:
• When removing each intake/exhaust valve
from the cylinder head, use a valve spring
compressor (see 10.1-4 in Chapter 10) and
2
compress the valve spring and remove the YE0390

valve cotter.
• Keep each removed intake/exhaust valve 2) Valve spring compressor
after attaching a tag showing the
corresponding cylinder No.
• If cotter burr is seen at the shaft of each intake/exhaust valve stem, remove it with an oilstone and extract
the valve from the cylinder head.
Reassemble:
• Replace the valve stem seal with a new one when an intake/exhaust valve is disassembled.
• Carefully install each valve after oil application so as not to damage the valve stem seal.
• Different valve stem seals are provided for the intake and exhaust valves. Do not confuse them since
those for exhaust valves are marked with yellow paint.
• After assembling the intake/exhaust valve, valve stem seal, valve spring, seat, and cotter, tap the head
of the valve stem lightly for settling.
• Do not forget to install the valve cap.

94E-98E SERIES 4-5

(1)
4. ENGINE BODY

(5) Parts Inspection and measurement

(5-1) Cylinder head
Clean the cylinder head, mainly the combustion surface, valve seats and intake/exhaust ports, remove
carbon deposit and bonding agent, and check the surface state.

(a) Appearance check

Check mainly discoloration and crack. If crack is suspected, perform color check.

(b) Combustion surface distortion

Apply a straight-edge in two diagonal 1
directions and on four sides of the cylin-
der head, and measure distortion with a
thickness gauge.

(Unit: mm)
Standard Limit

Distortion 0.05 or less 0.15

2 YE0391
Distortion at combustion surface
1) Straight-edge
2) Thickness gauge
3

(c) Valve sink

Measure with the valve inserted to the
cylinder head.

(Unit: mm)

Standard Limit

Valve Intake 0.5 – 0.7 1.0 YE0392

sink Valve sink

Exhaust 0.6 – 0.8 1.1

3) Depth micrometer

YE0393

Valve sink depth

(d) Seat width
4
(Unit: mm)

Standard Limit

Intake 1.3 2.0

Width
Exhaust 2.2 3.0

4) Valve caliper
YE0394

Valve seat width

4-6 94E-98E SERIES

(1)
 4. ENGINE BODY

(e) Seat contact

Apply a thin coat of minium on the valve
seat. Insert the valve in the cylinder and
push it against the seat to check seat
contact.

Standard: Continuous contact all

around 1

YE0395

Valve seat contact

1) Seat

(5-2) Valve guide

Mainly check damage and wear on the
inside wall. Apply supply part code 129150- 2 2 2
11810 when replacing the part.

(a) Inside diameter

(Unit: mm)

Standard Limit YE0396

Valve stem
7.965 – 7.980 7.915
O.D. Valve guide inside diameter
Intake valve

Valve 2) Measuring positions

8.015 – 8.030 8.100
guide I.D.

Valve
0.035 – 0.065 0.185
clearance

Valve stem
7.955 – 7.970 7.905
O.D.
Exhaust valve

Valve
8.015 – 8.030 8.100
guide I.D.
Valve
0.045 – 0.075 0.195
clearance

(5-3) Intake/exhaust valve

Mainly clean and check damage and wear
at the valve stem and seat. 3
(a) Seat cantact: See 5.1-(e) above.
(b) Stem outside diameter: See 5.2-(a)
above.

YE0397

Valve stem outside diameter

3) Measuring positions

94E-98E SERIES 4-7

(1)
4. ENGINE BODY

(c) Valve head thickness

(Unit: mm)
Standard Limit

Intake 1.71 1.00

Exhaust 1.65 1.00 4

YE0398

Valve head thickness

(d) Valve stem bend

5
Limit 0.01 mm

(e) Overall length

(Unit: mm) 6

Standard Limit

Intake 115 114.5

YE0399

Exhaust 115 114.5 Valve stem bend and length

4) Thickness 6) Stool
5) Length of valve

(5-4) Valve spring

Mainly inspect damage and corrosion. 1

(Unit: mm)

Standard Limit

Free length 47.5 —

Inclination — 1.2
YE0400

Valve spring

YE0401

Valve spring
1) Free length of spring 2) Inclination of spring

4-8 94E-98E SERIES

(1)
 4. ENGINE BODY

(5-5) Valve rocker arm

Mainly inspect valve head cap contact sur-
face, inside surface defects and wear.
Slight surface defects shall be corrected
with an oilstone.

(Unit: mm)

Standard Limit

Arm hole diameter 18.50 – 18.52 18.57

Shaft O.D. 18.47 – 18.49 18.44 YE0402

Rocker arm hole diameter
Clearance 0.01 – 0.05 0.13

(5-6) Valve rocker arm shaft

Mainly inspect seizure and wear at the sur-
face in sliding contact with the arm. The
rocker arm shaft diameter shall be as speci-
fied in (5-5) above.

YE0403

Rocker arm shaft outside diameter

(5-7) Push rod

Mainly inspect the surface in contact with
the tappet and adjusting screw. Slight
defects shall be corrected with an oilstone.

Bend limit 0.03 mm or less

3

(5-8) Valve clearance adjusting screw

YE0404
Mainly inspect the surface in contact with
the push rod. Push rod bend
Slight defects shall be corrected with an oil-
3) Thickness gauge
stone.

(5-9) Rocker arm spring

Mainly inspect surface defects and corro-
sion.

94E-98E SERIES 4-9

(1)
4. ENGINE BODY

(6) Valve seat correction

k Always check the oil clearance between the valve and valve guide before correcting the valve seat. If it
exceeds the limit, replace the valve or valve guide first to make the clearance satisfy the standard. After
correction, wash the valve and the cylinder head sufficiently with diesel oil to remove all grinding powder
or compound.

1. If the seat surface is slightly roughened:

1
perform [A] and [B] below.
2. If the seat is heavily roughened but the width 2
is almost normal, correct with a seat grinder
or seat cutter first. Then perform lapping [A]
and [B] below.

Intake Exhaust 3
Seat cutter angle
120° 90° YE0405
Seat cutter

3. If the seat is heavily roughened and the width

is much enlarged, grind the seat inner 4
surface with a seat grinder whose center
angle is 40°, then grind the seat outer
surface with a grinder whose center angle is
150° to make the seat width match the
standard. Then perform seat correction as
described in 2), and then carry out lapping
[A] and [B] below.
5 YE0406
Grinding wheel 1 2

angle Seat grinder

40° 150°

[A]: Lap the valve and seat with a mixture of

valve compound and engine oil.
[B]: Lap with engine oil only.

YE0407
Valve lapping
1) Seat angle
2) Seat width
3) Cylinder head correction angle
4) Grinder
5) Grindstone

4-10 94E-98E SERIES

(1)
 4. ENGINE BODY

(7) Valve guide replacement

2
1. Use a valve guide extraction tool (10.1-1 in
Chapter 10) and extract the valve guide from
the cylinder head. 3
2. Put liquid nitrogen or ether (or alcohol) with
dry ice added in a container and put the 1
valve guide for replacement (code No.
129150-11810) in it for cooling. Then insert it
in with a valve guide inserting tool (10.1-2 in
Chapter 10).
3. Check the inside diameter and finish to the 4
standard inside diameter as required with a
YE0408
reamer.
4. Check the projection from the cylinder head. Valve guide replacement
Projection: 14.7 – 15.0mm 1) Cylinder head
2) Valve guide extracting & inserting tool
3) Projection
4) Valve guide

k Do not touch the cooled valve guide with bare hands to avoid skin damage.

(8) Valve stem seal replacement

Always use a new seal after the intake/exhaust valve is disassembled. Since the one for the exhaust valve
is marked with yellow paint, do not confuse the intake and exhaust valves.
1. Apply engine oil to the lip.
2. Push with the inserting tool (10.1-5 in 5
Chapter 10) for installation.

YE0409

Stem seal insertion

5) Valve stem seal inserting tool
6) Valve stem seal
7) Valve guide
8) Cylinder head

94E-98E SERIES 4-11

(1)
4. ENGINE BODY

4.3 Gear train and camshaft

(1) Components

YE0410

1) Fuel injection pump drive gear 2) Lubricating oil pump

(2) Disassembly procedure:

Disassemble in the order of the numbers in the illustration.
Perform steps to of the cylinder head disassembly procedure.
Remove the cooling water pump.
Remove the crankshaft pulley. (Point 1)
Remove the gear case cover. (Point 2)
Remove the fuel injection pump. (Point 3)
Remove the idle gear ass’y. (Point 4)
Remove the PTO drive gear. (Point 5)
Remove the PTO lubrication pipe.
Remove the starting motor.
Remove the flywheel. (Point 6)
Remove the camshaft ass’y. (Point 7)
Remove the gear case. (Point 8)
Remove the oil seal from the gear case cover. (Point 9)

(3) Reassembly procedure:

Reverse of the disassembly procedure.

4-12 94E-98E SERIES

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 4. ENGINE BODY

(4) Servicing points

Point 1
Disassemble:
• Remove the crankshaft pulley using a gear puller after removing the mounting bolt. When removing the
pulley with the gear puller, use a pad and carefully operate so as not to damage the thread. Set the gear
puller securely to prevent the pulley from being damaged.
Reassemble:
• When installing the crankshaft pulley, apply lube oil to the bolt and carefully assemble so as not to

3 Bolt: 107.8 – 127.4 Nm {11 – 13 kgm}

damage the oil seal.

Point 2
Reassemble:
• When installing the gear case cover, do not forget to install the two reinforcing bolts at the center.
• Measure the backlash of each gear.

(Unit: mm) 1
2
Standard Limit

Crankshaft gear,
camshaft gear,
Fuel injection 0.08 – 0.14 0.16
7
pump gear, Idle
gear, PTO gear 3
4
Lubricating oil 6
0.09 – 0.15 0.17 5
pump gear YE0411

Gear train
• Apply sealant and install the gear case cover
by correctly positioning the two dowel pins. 1) Fuel injection pump 5) Direction of rotation
drive gear 6) Lubricating oil pump
2) Camshaft gear gear
3) PTO gear 7) Idle gear
4) Crankshaft gear

Point 3
Disassemble:
• Remove the fuel injection pump drive gear mounting nut, remove the gear using the gear puller, and
remove the fuel injection pump. Do not forget to remove the stay on the rear side. When extracting the
gear using the gear puller, use a pad at the shaft and carefully operate so as not to damage the thread.

• 3 Fuel injection pump drive gear nut: 83.3 – 93.1 Nm {8.5 – 9.5 kgm}
Reassemble:

Point 4
Reassemble:
• Assemble crankshaft gear A, fuel injection pump drive gear B and camshaft gear C at the same time by
aligning with idle gear A, B and C marks.
• Install the idle gear shaft with the oil hole facing upward.

Point 5
Reassemble:
• Install the PTO gear with its inner spline side facing the flywheel.

94E-98E SERIES 4-13

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4. ENGINE BODY

Point 6
Disassemble:
• Install a bolt as a handle in the hole at the end face of the flywheel and remove carefully so as not to
damage the ring gear.

• 3 Flywheel mounting bolt: 186.2 – 205.8 Nm {19 – 21 kgm}, apply lube oil
Reassemble:

Point 7 1
Disassemble:
2
• Measure the camshaft end play.

(Unit: mm)
Standard Limit

End play 0.05 – 0.20 0.30

• If the measured end play exceeds the limit,

replace the thrust metal.
Disassemble: 3
• Since the camshaft gear is shrink-fit, heat it YE0412
to 180 – 200°C for extraction. Camshaft end play
• For camshaft removal, raise the engine with
its mounting flange at the bottom. After 1) Camshaft gear
removing the thrust metal mounting bolt from 2) Thrust metal
the camshaft gear hole, extract the camshaft 3) End play
carefully so as not to damage the bearing
bushing.
• Rotate the camshaft a few turns before extracting it to prevent the tappet from being caught by the cam.
• After removing the camshaft, set the engine horizontal and fix it on the base.

k Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to
the horizontal position. Proceed carefully so as not to lose balance.

Point 8
Reassemble:
• Do not forget to install the oil pan mounting bolts on the bottom side when installing the gear case.
• Apply sealant (code No.977770-01212) and install the gear case by matching the two dowel pins.

Point 9
Reassemble:
• Replace the oil seal whenever disassembled.
• Apply lithium grease at the time of assembly.

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 4. ENGINE BODY

(5) Parts inspection and measurement

(5-1) Camshaft
Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and
gear damage.

1. Camshaft bend measurement

Support the camshaft with V blocks. Rotate 1
the camshaft and measure the runout at the
center of the camshaft and at each journal
with a dial gauge. Half of the runout is the
bend.

(Unit: mm)

Standard Limit 2
Bend 0 – 0.02 0.05 YE0413

Camshaft bend
2. Intake/exhaust cam height measurement

(Unit: mm)

Standard Limit
3 4
Cam height 42.435 – 42.565 42.185

3. Camshaft outside diameter and bearing hole

diameter measurement
Measure the camshaft outside diameter with YE0414
a micrometer. The oil clearance shall be
calculated by subtracting the measured
Cam height
camshaft outside diameter from the camshaft
bushing inside diameter after insertion to the
cylinder measured with a cylinder gauge.

(Unit: mm)
5
Standard Limit 6

Camshaft O.D. 49.925 – 49.950 49.890

Gear side

Bushing I.D. 49.990 – 50.055 50.130

Oil clearance 0.040 – 0.130 0.240

Wheel side Intermediate

Camshaft O.D. 49.910 – 49.935 49.875 YE0415

position

Block I.D. 50.000 – 50.025 50.100 Camshaft outside diameter

Oil clearance 0.065 – 0.115 0.225 1) Dial gauge

2) V-block
Camshaft O.D. 49.925 – 49.950 49.890 3) Cam height
Block I.D. 50.000 – 50.025 50.100 4) Micrometer
5) Flywheel side
Oil clearance 0.050 – 0.100 0.210
6) Micrometer

94E-98E SERIES 4-15

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4. ENGINE BODY

(5-2) Idle gear

Mainly check the bushing seizure and wear,
and gear damage. 7 10
1. Idle gear shaft outside diameter and bushing
inside diameter measurement

(Unit: mm) 8 9

Standard Limit

Idle gear shaft outside

45.950 – 49.975 45.900
diameter YE0416

Bushing inside diameter 46.000 – 46.025 46.075

Idle gear
Clearance 0.025 – 0.075 0.175
7) Idle gear shaft 9) Inside diameter of gear
8) Shaft diameter 10) Idle gear

(5-3) PTO gear

Mainly check sticking of bearings on both sides, gear damage and looseness, and gear shaft damage
and wear.

(6) Oil seal replacement

1. Replace the oil seal with a new one when the gear case is disassembled. Extract the used oil seal.
2. Insert a new oil seal using the oil seal inserting tool.
3. Apply Lithium grease.

(7) Camshaft bushing replacement

Replace the bushing using the special service tool (see 10.1-7 in Chapter 10).

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 4. ENGINE BODY

4.4 Cylinder block

(1) Components

YE0417

1) Oil filter

(2) Disassembly procedure:

Disassemble in the order of the numbers in the illustration.

Perform steps to in the cylinder head disassembly procedure.

Perform steps to in the gear train disassembly procedure.
Remove the oil pan. (Point 1)
Remove the lubricating oil suction pipe.
Remove the piston w/rod. (Point 2)
Remove the flywheel housing. (Point 3)
Remove the bearing metal caps. (Point 4)
Remove the crankshaft. (Point 5)
Remove the tappets.
Remove the piston and piston rings. (Point 6)
Remove the oil seal from the flywheel housing. (Point 7)

94E-98E SERIES 4-17

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4. ENGINE BODY

(3) Reassembly procedure:

Reverse of the disassembly procedure.

(4) Servicing points

Point 1 Oil pan
Disassemble:
• Sealant is applied to the oil pan mounting
surface on the cylinder block. Carefully operate
so as not to damage or distort the bonding
surface.
Reassemble:
• Apply sealant (code No.977770-01212)
before reassembly.

Point 2 Piston w/rod 1

Disassemble:
2
• Measure the connectiong rod side gap.

Standard 0.20 – 0.40 mm

YE0418
• Carefully remove the carbon deposit on top
Connecting rod side gap
of the cylinder block so as not to damage the
inner side of the cylinder block. 1) Crankshaft
• Set the piston at the B.D.C. position and 2) Thickness gauge
remove the connecting rod cap. Then set the
piston at the T.D.C. position, and push the
connecting rod big end with the wooden shaft
of a hammer. Proceed carefully so as not to
cause the cylinder block catch the rod big
end. Set the connecting rod caps and
crankpin metals in their correct combinations.
Reassemble:
• Apply oil especially carefully to the sliding contact surfaces of the pistons, rods and rings.
• Use the piston insertion tool (See 10.1-9 in Chapter 10) to insert each piston w/rod in the cylinder block

3 Connecting rod metal cap mounting bolt: 53.9 – 58.8 Nm {5.5 – 6 kgm}, apply lube oil
and install the bearing metal cap.

Point 3 Mounting flange

Disassemble:
Place the engine on a stable base with the cylinder block upper surface facing down, and remove the
flywheel housing carefully so as not to damage the combustion surface.
Reassemble:
Apply sealant (code No.977770-01212) and install the flywheel housing by matching the two dowel
pins. After assembly, raise the engine with its mounting flange on the bottom side.

k Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Carefully
operate so as not to lose balance.

4-18 94E-98E SERIES

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 4. ENGINE BODY

Point 4 Journal bearing cap

Disassemble:
• Before removing the main journal bearing,
measure the crankshaft end play.

(Unit: mm)
Standard Limit

0.11 – 0.21 —

YE0419

Crankshaft end play

Reassemble:
• If the end play exceeds the standard, replace
the thrust metal with an oversize one.

0.25 mm OS 129900 – 02370 (Upper)

Code No. 129900 – 02360 (Lower)
Standard thickness 2.055 – 2.105 mm

Disassemble:
• Remove the main metal caps, cap side 2
bearings, and thrust metals. Place each 1 3
thrust metal with identification of the position
and direction. 4

Reassemble:
• Carefully install each thrust metal so that the
grooved one is positioned away from the
cap.
• Do not confuse the upper and lower main 5
bearing metals. The upper main bearing
metal (cylinder block side) has an oil hole,
and the lower one does not. The "wheel and
arrow" marks on the cap shall face the YE0420
flywheel. Main bearing
1) Flywheel side 4) Cap side main
2) Thrust metals bearing metals
3) Cylinder block side 5) Timing gear side
main bearing metals

3 Main metal cap mounting bolt: 107.8 – 117.6 Nm {11 – 12 kgm}

lubrication oil application

Point 5 Crankshaft
Disassemble:
• Remove the crankshaft. Remove each main bearing metal upper (cylinder block side) and pair it with the
main metal cap side lower metal.

k Carefully prevent damage to the bearing or finger injury when removing the crankshaft because it is
heavy.

94E-98E SERIES 4-19

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4. ENGINE BODY

Point 6 Piston pin and rings

Disassemble:
• Use the piston ring replacer (See 10.1-10 in
Chapter 10), remove the piston rings.
• Remove the circlip and remove the piston
pin by pushing it out.
Reassemble:
• Install each piston ring on the piston, with the 1
pu nch ed manu fac ture r’ s ma rk faci ng
upward. YE0421

Piston ring
Reassemble:
• The piston ring joints shall be staggered at 2
by 120° intervals. Do not position the top ring
joint vertical to the piston pin. The coil
expander joint shall be opposite to the oil ring
joint. 5

3
1) Punched manufacturer’s
mark (make it face
upward.)
2) Oil ring joint
3) Top ring joint 4
4) Expander joint
5) Second ring joint

YE0422
Ring joints

Reassemble: 7
• When installing the piston pin to the connect-
ing rod and piston, the punched match mark
on the big end of the connecting rod shall be 6 8
opposite to the size mark on the piston top.
Reassemble:
• Install the piston in the cylinder block with the
9
punched mark on the big end of the connect- 10
ing rod on the nozzle side. (The embossed
mark at the connecting rod I-beam section 11
shall be on the flywheel side.)

6) Camshaft side
12
7) Piston ID mark
8) Fuel injection
nozzle side 13
9) Cylinder block
size mark
10) Flywheel side
11) Piston ID mark
YE0423
12) Embossed mark
Assembly direction of connecting rod
(flywheel side)
and piston
13) Match mark

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 4. ENGINE BODY

Point 7 Oil seal

Reassemble:
• Replace the oil seal with a new one whenever disassembled. Apply lithium grease at the time of
assembly.

(5) Parts inspection and measurement

(5-1) Cylinder block
Especially clean head surface, cylinder bores and oil holes, and check after removing any carbon
deposit and bonding agent.

1. Appearance inspection
Check if there is any discoloration or crack.
If crack is suspected, perform color check.
Sufficiently clean the oil holes and check
they are not clogged.
2. Cylinder bore and distortion
Measure at 10 mm below the crest of the
liner, at 20 mm from the bottom end and at
the center.
Roundness: Maximum value of the differ-
ence between the measured
values in the same cross sec- YE0424
tion. Cylinder bore
Cylindricity: Maximum value of the differ-
ence between the measured
values in the same direction. 10mm

(Unit: mm)

Standard Limit

4D94E 94.000 – 94.030 94.130

Bore
4D98E 98.000 – 98.030 98.130
20mm
Roundness 0.01 or less 0.03

Cylindricity 0.01 or less 0.03 YE0425

Cylinder bore measurement positions

Measure in two directions A and B at points a, b and
3. If the limit is exceeded or any surface defect c.
is found, repair by boring and honing. Use an
oversized piston (and new piston rings) as
required.

Piston ass’y code Boring dimension

0.25 mm OS Piston ring ass’y code Head gasket code
(incl./Piston ring ass’y) (mm)

4D94E 129900-22900 129901-22950 94.250 – 94.280 129900-01331 (STD)

4D98E 129902-22900 129903-22950 98.250 – 98.280 129902-01330 (STD)

Piston ass’y code Boring dimension

0.50 mm OS Piston ring ass’y code Head gasket code
(incl./Piston ring ass’y) (mm)

4D94E 129900-22920 129901-22970 94.500 – 94.530 129900-01340 (OS)

4D98E 129902-22920 129903-22970 98.500 – 98.530 129902-01340 (OS)

94E-98E SERIES 4-21

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4. ENGINE BODY

(5-2) Crankshaft
Mainly check seizure and wear of the crank-
pins and main journals. Since the crankshaft
gear is shrink-fitted, heat to 180 to 200°C
when extraction is necessary.
1. Shaft portion color check
After washing the crankshaft, inspect it by
means of color check or a magnaflux
inspector. Replace it if cracked or heavily
damaged. Slight defects shall be corrected
by grinding.
2. Crankshaft bend
Support the crankshaft journals at both ends
YE0426
with V-blocks. Use a dial gauge and mea-
sure the runout at the center journal while Inspection by color check
rotating the shaft to inspect the bend.

Limit 0.02 mm or less 1

2
3

4 5
YE0427

Crankshaft bend measurement

1) Bend
2) Deflection
3) Dial gauge
4) V-block
5) V-block

4-22 94E-98E SERIES

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 4. ENGINE BODY

3. Crankpin and main journal measurement

Masure the outside diameter, roundness
and taper at each crankpin and main jour-
nal.
Correct by grinding if unevenly wear, round-
ness exceeding the limit or insufficient out-
side diameter is found. Replace if the defect
is excessive.

• Crankpin (Unit: mm)

Standard Limit
Crankpin outside
57.952 – 57.962 57.902
diameter

Connecting rod
1.492 – 1.500 —
metal thickness

Oil clearance 0.038 – 0.074 0.150

If the oil clearance exceeds the limit, use an

undersized bearing.

0.25 mm US bearing 6
7
Part code 129900-23350 YE0428

Standard thickness 1.617 – 1.625 mm Measuring position of the crankpin

and crank journal
Crankpin machining
57.502 – 57.712 mm
dimension 6) Crankshaft journal 7) Crankpin

• Crank journal (Unit: mm)

0.25 mm US Crank journal bearing
Standard Limit
129900-02320 (Upper)
Part code
Journal O.D. 64.952 – 64.962 64.902 129900-02330 (Lower)

Main metal Standard thickness 2.215 – 2.130 mm

1.995 – 2.010 —
thickness
Main journal bearing
machining dimension 64.702 – 64.712 mm
Oil clearance 0.038 – 0.068 0.150

If the clearance limit is exceeded, use an

undersized bearing.
a If the oil clearance is execessive though the thicknesses of the main journal and crankpin metals are
normal or if partial uneven wear is observed, re-grind the crankshaft and use an oversized metals.
a If rust of surface roughening exists on the rear side of the metals, coat it with blue or minimum. Then
assemble the crankpin metal to the connecting rod, and tighten the rod bolt to the specified torque to
check the metal for contact. If the contact surface occupies 75% or more, the metal is normal. If the
contact surface is insufficient, the metal interference is insufficient. Replace the metal with a new one.

94E-98E SERIES 4-23

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4. ENGINE BODY

(5-3) Thrust metal inspection

Inspect any damage or wear.
1. Thrust metal thickness (Unit: mm)

Standard Limit
Thickness 1.930 – 1.980 1.850

If the side gap is exceeded, use an oversized thrust metal.

0.25 mm OS 129900-02370 (Upper)

Code No. 129900-02360 (Lower)
Standard thickness 2.055 – 2.105 mm

(5-4) Piston
Especially clean the combustion surface,
circumference, ring grooves and piston pin
bosses, and check after removing any car-
bon deposit. Any burr at a ring groove or
snap ring groove shall be removed. If crack
is suspected, inspect by color check.

1) Measurement position

1. Piston outside diameter mesurement

Measure the long diameter at 22 mm from 1
22mm
the bottom end of the piston of the oval hole YE0429
in the vertical direction to the piston pin hole. Piston outside diameter
(Unit: mm)

Standard Limit

Long 4D94E 93.945 – 93.955 93.900

diameter 4D98E 97.945 – 97.955 97.900

Clearance Min. — 0.050

between piston
and cylinder Max. — 0.080 YE0430
Piston pin outside diameter
Measure at positions a, b and c in directions A and B.
If the clearance between piston and cylinder
exceeds the limit, use an oversized piston.

Piston ass’y code Boring dimension

0.25 mm OS Piston ring ass’y code Head gasket code
(incl./Piston ring ass’y) (mm)

4D94E 129900-22900 129901-22950 94.250 – 94.280 129900-01331 (STD)

4D98E 129902-22900 129903-22950 98.250 – 98.280 129902-01330 (STD)

Piston ass’y code Boring dimension

0.50 mm OS Piston ring ass’y code Head gasket code
(incl./Piston ring ass’y) (mm)

4D94E 129900-22920 129901-22970 94.500 – 94.530 129900-01340 (OS)

4D98E 129902-22920 129903-22970 98.500 – 98.530 129902-01340 (OS)

4-24 94E-98E SERIES

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 4. ENGINE BODY

2. Piston pin hole measurement

(Unit: mm)
Standard Limit

Piston pin hole

30.000 – 30.009 30.039
diameter

Piston pin outside

29.989 – 30.000 29.959
diameter

Oil clearance 0.000 – 0.020 0.080 YE0431

Piston pin hole
Measure at positions a and b in directions A and B.

3. Piston ring, ring groove and piston ring end

clearance measurement 1
• Except for the top ring, to measure the
piston ring groove width, first measure
the width of the piston ring. Then insert
2
the piston ring into the ring. Then insert
the piston ring into the ring groove. Insert
a thickness gauge in between the piston 3
ring and groove to measure the gap
between them. Obtain the ring groove
wi dth by ad ding r ing width to the
measured side clearance.
YE0432
Piston ring components
1) Top ring
2) Second ring
3) Oil ring
4) Width
5) Thickness

5
YE0433

Measuring side clearance

94E-98E SERIES 4-25

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4. ENGINE BODY

• To measure the piston ring end clearance,

push the piston ring into the sleeve using 6
the piston head, insert a thickness gauge
in end clearance to measure. The ring
7
shall be pushed in to approx. 30 mm
above the bottom end of the cylinder. For
the top ring, measure only the piston ring
joint end clearance in normal state.

(Unit: mm) 10 8
9
Standard Limit YE0434

Ring joint end clearance measurement

Piston ring groove
2.040 – 2.060 —
width 6) Cylinder block head surface
Piston ring width 1.940 – 1.960 1.920 7) Joint end clearance
Top ring

8) Approx. 30 mm from bottom end of cylinder

Piston side 9) Piston ring
0.080 – 0.120 —
clearance
10) Cylinder block
Piston end
0.250 – 0.450 0.540
clearance

Piston ring groove

2.080 – 2.095 2.195
width
Second ring

Piston ring width 1.970 – 1.990 1.950

Piston side
0.090 – 0.125 0.245
clearance

Piston end
0.450 – 0.650 0.730
clearance
Piston ring groove
3.015 – 3.030 3.130
width

Piston ring width 2.970 – 2.990 2.950

Oil ring

Piston side
0.025 – 0.060 0.180
clearance

Piston end
0.250 – 0.450 0.550
clearance

4-26 94E-98E SERIES

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 4. ENGINE BODY

(5-5) Connecting rod

1. Appearance inspection
Inspect the portion near the boundary of the
chamfered portion and I-beam section of the
big and small ends of the connecting rod as 1
well as the portion near the oil hole of the
bushing at the small end for cracks, defor-
mation, and discoloration.

2. Twist and parallelism measurement

Use a connecting rod aligner and measure 2
the twist and band. 3

(Unit: mm)
YE0435
Standard Limit
dimension dimension Twist and parallelism measurement

Twist and 0.03 or less

0.08
parallelism per 100

3. Connecting rod small end measurement

Measure the piston pin outside diameter 4
according to (5-4) -1 described above.

(Unit: mm)
Standard Limit

Piston pin I.D.

30.025 – 30.038 30.068 YE0436
bushing
Twist measurement using
Piston pin O.D. 29.987 – 30.000 29.959
a connecting rod aligner
Oil clearance 0.025 – 0.051 0.109

If the bushing is to be replaced because the

oil clearance exceeds the limit, use spare
part code No. 129900-23910.

4. Connecting rod big end measurement

Measure the crankpin and metal according
to (5-2) -3 described above.

YE0437

Connecting rod small end

1) Parallelism 4) Connecting rod aligner
2) Twist 5) Cylinder gauge
3) Mandrel

94E-98E SERIES 4-27

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4. ENGINE BODY

(5-6) Tappet
Mainly check the tappet contact surface with
the cam and push rod. Slight surface
defects shall be corrected with an oilstone.

1. Tappet stem outside diameter measurement

(Unit: mm)
Standard Limit

Tappet stem
11.975 – 11.990 11.955
O.D.
1 2 YE0438
Tappet hole I.D. 12.000 – 12.018 12.038
Tappet
Oil clearance 0.010 – 0.043 0.083
1) Abnormal contact surface
2) Normal contact surface

YE0439

Tappet stem outside diameter measurement

(6) Cylinder bore correction

1. Slight uneven worn, flawed, etc. shall be
corrected by honing only. If the cylinder is
unevenly worn partially, flawed or otherwise
damaged and cannot be repaired simply by
honing, rebore the cylinder first and then
hone. See (5) (5-1)-3 for the boring 4
dimension.
2. Items to be prepared for honing 6 7
• Flex-Hone (see 10.1-8 in Chapter 10) 50% 50%
• Electric drill
• Honing fluid (50:50 mixture of lube oil
and diesel oil) 3
5 YE0440
Items to be prepared for honing
3) Flex-hone
4) Electric drill
5) Honing fluid
6) Lube oil
7) Diesel oil

4-28 94E-98E SERIES

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 4. ENGINE BODY

3. Apply the honing fluid to the Flex-Hone and

turn the electric drill at 300 to 1200 rpm.
Then insert the Flex-Hone into the cylinder
bore while turning it, and move it up and
down for about 30 sec. to obtain a honing
mark with a cross hatch angle of 30 to 40°.

YE0441
Honing cross hatch

k Avoid faster revolution than 1,200 rpm since it may cause breakdown.
k Do not insert or extract the Flex-Hone in stopped state because the cylinder will be damaged.

• Cylinder overhaul (reference)

Service life of cylinder block (H3)

(H3 = 3H1)

Boring and honing interval (H2)

(H2 = 1.5H1)

Time for honing (H1)

Increase in
Increase in lubricating Increase in lubricating Increase in lubricating lubricating
oil consumption oil consumption oil consumption oil consumption
or blow-by or blow-by or blow-by or blow-by

Honing Boring Honing

(Study if an oversized piston or piston ring is usable.)

YE0568

(7) Piston pin bushing replacement

Replace bushing by using the special service tool (see 10.1-3 in Chapter 10).

(8) Oil seal replacement

1. Replace oil seal, when flywheel housing is removed. Extract the used oil seal.
2. Insert a new oil seal with the oil seal insertion tool.
3. Apply lithium grease.

94E-98E SERIES 4-29

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 5. LUBRICATION SYSTEM

5. LUBRICATION SYSTEM

5.1 Lubrication system diagram ................................................................................................................... 5- 2

5.2 Trochoid pump components .................................................................................................................. 5- 2
5.3 Disassembly (reverse the procedure below for assembly) .................................................................... 5- 3
5.4 Servicing points ..................................................................................................................................... 5- 3
5.5 Parts inspection and measurement ....................................................................................................... 5- 4

94E-98E SERIES 5-1

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5. LUBRICATION SYSTEM

5.1 Lubrication system diagram

2 3 4

7
8
5
YE0443

1) Crankshaft bearing 5) Oil pan

2) Camshaft bearing 6) Lube oil pump
3) To cylinder head (with built-in pressure regulator valve)
(valve rocker arm lubrication) 7) Fuel injection pump
4) To gear case 8) Lube oil filter
(oil pump gear lubrication)

5.2 Trochoid pump components

1) Outer rotor 2
2) Gear case
3) Crankshaft
4) Punch mark 1

4
3
YE0444

5-2 94E-98E SERIES

(1)
 5. LUBRICATION SYSTEM

5.3 Disassembly (reverse the procedure below for assembly)

1. Loosen the belt, and remove the radiator pulley, fan and V-belt. See 4.2 (2) 2 in Chapter 4.
2. Remove the crankshaft pulley. See 4.3 (2) in Chapter 4.
3. Remove the gear case cover. See 4.3 (2) in Chapter 4.
4. Remove the lubricating oil pump ass’y from the gear case. (Point 1)
5. Remove the pressure regulator valve from the lubricating oil pump body. (Point 2)

5.4 Servicing points

Point 1
Disassemble:
• Check if the oil pump rotates smoothly and see that there is no play between the shaft and gear, and
inner rotor.
Reassemble:
• Install the outer rotor in the gear case so that the punch mark on the end face is seen.
• When replacing the lubricating oil pump, replace the whole ass’y.

Point 2
Disassemble-Reassemble:
• Only wash the pressure regulator valve. Disassembly is unnecessary unless any abnormality in
operation is detected.

94E-98E SERIES 5-3

(1)
5. LUBRICATION SYSTEM

5.5 Parts inspection and measurement

(1) Outer rotor
• Oil clearance between the outer rotor and
inside diameter of the gear case hole. 2
• Side clearance between outer rotor and gear
1
case hole.

(Unit: mm)

Standard Limit

Oil clearance 0.100 – 0.155 0.25

Side clearance 0. 05 – 0.10 0.15
YE0445

(2) Rotor shaft Oil clearance

(Unit: mm)

Standard Limit

Shaft O.D. 12.955 – 12.970 12.945

Bearing I.D. 12.980 – 13.020 13.050

Clearance 0.010 – 0.065 0.105

YE0446

Side clearance

4 5

6
YE0447

Lube oil pump bearing

1) Gear case
2) Outer rotor
3) Rotor shaft
4) Shaft O.D.
5) Bearing I.D.
6) Gear case

5-4 94E-98E SERIES

(1)
 6. COOLING SYSTEM

6. COOLING SYSTEM

6.1 Cooling water system ............................................................................................................................ 6- 2

6.2 Cooling water pump components .......................................................................................................... 6- 3
6.3 Disassembly (reverse the procedure below for assembly) .................................................................... 6- 3
6.4 Servicing points ..................................................................................................................................... 6- 3

94E-98E SERIES 6-1

(1)
6. COOLING SYSTEM

6.1 Cooling water system

2
4

YE0448

1) From cylinder head

2) Cooling water pump
3) Radiator
4) Bypass

6-2 94E-98E SERIES

(1)
 6. COOLING SYSTEM

6.2 Cooling water pump components

YE0449

1) Cylinder head
2) Gear case

6.3 Disassembly (reverse the procedure below for assembly)

1. Remove the alternator. See 4.2 (2) - in Chapter 4.
2. Remove the fan, fan V-belt and fan pulley. See 4.2 (2) - in Chapter 4.
3. Remove the thermostat cover. See 4.2 (2) - in Chapter 4.
4. Remove the cooling water pump. (Point 1)
5. Remove the thermostat. (Point 2)

6.4 Servicing points

Point 1
Disassemble-Reassemble:
• Check to see that the cooling water pump bearing is free from abnormal noise, sticking or play and water
leakage from the bearing. If replacement is necessary, replace the whole cooling water pump ass’y.

Point 2
Disassemble:
• Check the thermostat function. See 3.9-1 (1) in Chapter 3 for the inspection method.

94E-98E SERIES 6-3

(1)
 7. FUEL INJECTION PUMP/GOVERNOR

7. FUEL INJECTION PUMP/GOVERNOR

7.1 Introduction ............................................................................................................................................ 7- 2

7.2 Fuel injection pump................................................................................................................................ 7- 2
7.3 Fuel injection nozzle .............................................................................................................................. 7- 9
7.4 Fuel feed pump ...................................................................................................................................... 7- 9
7.5 Governor .............................................................................................................................................. 7- 11
7.6 Special service tools for disassembly/assembly .................................................................................. 7- 12

94E-98E SERIES 7-1

(1)
7. FUEL INJECTION PUMP/GOVERNOR

7.1 Introduction
Zexel (Bosch)’s products are adopted as the fuel injection pump and governor for this engine. Because of
the need of implementing the special service tools including the pump test stand, extract from Zexel’s Ser-
vice Manual is summarized here to enable disassembly, inspection and maintenance in an emergency. The
portions not described in this manual, therefore, should not be disassembled and adjusted. When detailed
adjustment is needed, contact Zexel and ask their service.

7.2 Fuel injection pump

(1) Fuel system diagram

3
4

1
5
YE0450

1) Fuel filter
2) Fuel injection nozzle
3) Fuel injection pump
4) Fuel pump
5) Fuel tank

7-2 94E-98E SERIES

(1)
 7. FUEL INJECTION PUMP/GOVERNOR

(2) Components

YE0451

NOTE: This illustration is the standard components for the PES-A type.
The shapes of some parts are differrent from those of the fuel injection pump for this engine.

(3) Disassembly procedure

(3-1) Disassembly from the engine body
Remove the cooling fan, fan pulley and fan V-belt. See 4.2 (2) in Chapter 4.
Remove the fuel injection pipe, fuel oil piping, fuel return pipe and rear stay. See 4.2 (2)- in
Chapter 4.
Remove the fuel injection pump drive gear cover. See 4.3 (1) in Chapter 4.
Remove the fuel injection pump drive gear. See 4.3 (1) in Chapter 4. (Point 1)
Remove the fuel injection pump. See 4.3 (2) - in Chapter 4.

(3-2) Fuel injection pump disassembly

Remove the fuel feed pump. See 7.4 (1) Components.
Remove the governor cover. See 7.5 (1) Components. (Point 2)
Remove the governor housing. See 7.5 (1) Components. (Point 3)
Remove the bottom screw from the bottom. (Point 4)
Remove the fuel injection pump cover.
Bring the tappet away from the camshaft. (Point 5)
Remove the bearing holder. (Point 6)
Remove the camshaft. (Point 7)
Remove the tappet. (Point 8)
Remove the plunger, spring and spring retainer, control sleeve and pinion.
Remove the lock plate, and remove the delivery valve, holder and spring.
Remove the plunger & barrel.
Remove the control rack from the pump housing.

94E-98E SERIES 7-3

(1)
7. FUEL INJECTION PUMP/GOVERNOR

k Tappets, shims, springs, spring retainer, plunger & barrel, delivery valves, springs and delivery valve holders
shall be grouped for each cylinder to enable mounting at original positions unless abnormalities are found.

(4) Assembly procedure

Reverse the disassembly procedure.

(5) Servicing points

Point 1 2
Disassemble:
• Remove the fuel injection pump drive gear
and idle gear after putting a match mark.
Reassemble: 1
• Assemble them by aligning the match marks. 3

3 Pump drive gear nut: YE0452

83.3 – 93.1Nm {8.5 – 9.5kgm}
Gear
1) Fuel injection pump drive gear
2) Match mark
3) Idle gear

Point 2
Disassemble:
• Governor cover removal (See 7.5 (1) Governor components.)
Because the link is connected to the control rack and the starting spring is connected to spring connec-
tion plate, disconnect the link connection by shifting the governor cover to the left (or right) after pushing
the link leaf spring down with a screwdriver and disconnect the starting spring from the spring connec-
tion plate with long-nosed pliers before separating the governor cover from the governor housing.

k When removing the governor cover,

carefully operate so as not to bend the
governor cover to either side from the
governor housing. If the governor cover 5
is bent while the link is connected, the
link is bent to increase the sliding
resistance of the control rack upon 4
completion of the governor assembly,
resulting in stiff governor movement.

6
YE0453

Governor cover removal

4) Governor cover
5) Screwdriver
6) Governor housing

Reassemble:
• Coat sealant (code No.977770-01212) on the mating faces of the governor cover and governor housing.

7-4 94E-98E SERIES

(1)
 7. FUEL INJECTION PUMP/GOVERNOR

Point 3
Disassemble:
• Governor housing removal (See 7.5 (1)
1
Governor components.)
a) To remove the flyweight from the 2
camshaft, first use the special wrench
(157915-0100) and remove the
camshaft nut and spring washer. Then,
screw the extractor (157926-5110) into
the flyweight holder threaded portion
and remove the flyweight ass’y.
b) To remove the governor housing from the
injection pump housing, insert the tappet
YE0454
holder (157931-2500) first between the
tappet adjusting bolt and nut in the pump Flyweight removal
housing to disconnect the camshaft and
t app et. T he n r emo ve se ve n bol ts 1) Governor housing
fastening the governor housing. Remove 2) Extractor
the governor housing by tapping it with a
wooden or plastic hammer.

3 Flyweight mounting nut: 53.9 – 63.7 Nm {5.5 – 6.5 kgm}

Reassemble:

• Coat sealant (code No.977770-01212) on the mating faces of the governor housing and pump housing.

Point 4
Disassemble-Reassemble:
• Remove the bottom screw by using a socket wrench handle.

Point 5
Disassemble:
• To separate between the tappet and the
cam, place the cam at the T.D.C. and insert
the special service tool (tappet holder) into
the hole in the tappet. (Zexel’s code
No.157931-2500)

1) Tappet holder
2) Protective tape
1
YE0455

Point 6
Disassemble:
• When removing the bearing cover, wrap oil
seal protecting tape on the key groove and 2
thread. (Take this action also at the time of
assembly.)
• Tap the camshaft from the opposite side.
• Insert a screwdriver into the gap and pry for
removal.

YE0456

94E-98E SERIES 7-5

(1)
7. FUEL INJECTION PUMP/GOVERNOR

Point 7
Disassemble:
• Set the drive side cam at the T.D.C. and pull
the camshaft toward the drive side for
removal.

YE0457

Point 8 1 2
Disassemble:
• For tappet removal, push the tappet roller up
with the tappet insert from below to remove
the tappet holder, and take the tappet out
from the camshaft hole with the clamp.

Zexel’s codes
Tappet insert: 157921-0120
Clamp: 157931-6120
YE0458

1) Holder
2) Tappet insert
3) Clamp

3 YE0459

(6) Parts inspection and measurement

(6-1) Pump housing
Mainly check for crack, wear and damage at
threaded hole.
(6-2) Springs and delivery valve plunger
Mainly check for surface defect, crack,
uneven wear, corrosion and rust.
(6-3) Plunger & barrel
Check for suface defect, uneven corrosion
and wear mainly at the lead portion. After
washing, tilt the barrel by around 60°. YE0460
Pull the plunger out and release it. The Fall by gravity test of plunger and barrel
state is normal if the plunger slips down
smoothly by its own weight. Test several
times while turning the plunger to different
angles.

7-6 94E-98E SERIES

(1)
 7. FUEL INJECTION PUMP/GOVERNOR

(6-4) Delivery valve

Mainly check for surface defect, corrosion
and wear mainly at the piston.

YE0461

Delivery valve

(6-5) Check mainly the control rack for bend, the

pinion for wear and damage at the gear
portion, and the sleeve for wear at the
contact face with the plunger collar portion.

YE0462
Rack, pinion and sleeve

(6-6) Tappet
Check mainly for wear and damage at the
pin hole, roller, pin and bushing.

YE0463

Tappet

(6-7) Camshaft
Check mainly the cam surface for damage
and wear, the key groove and thread for
deformation, and the shaft for bend.

(6-8) Bearing
Check mainly the roller bearing for wear,
and the outer race for surface defect.
YE0464

Camshaft

94E-98E SERIES 7-7

(1)
7. FUEL INJECTION PUMP/GOVERNOR

(6-9) Plunger spring lower retainer

Check mainly the portion in contact with the
plunger for deformation and wear.

YE0465

Plunger spring lower retainer

7-8 94E-98E SERIES

(1)
 7. FUEL INJECTION PUMP/GOVERNOR

7.3 Fuel injection nozzle

Point 1
Disassemble:
• Check the fuel injection pressure and spray pattern. See 3.6 in Chapter 3 for the inspection method.

7.4 Fuel feed pump

(1) Components

1 2 3
5

6
YE0466

1) Snap ring 3) Check valve 5) Check valve

2) Tappet ass’y 4) Priming pump 6) Plug

(2) Disassembly procedure (Reverse the procedure below for assembly.)

1. Remove the fuel feed pump ass’y from the fuel injection pump.
2. Remove the priming pump and check valve.
3. Remove the plug and check valve from the fuel outlet side.
4. Remove the plug, and remove the piston.
5. Remove the snap ring, and remove the tappet ass’y, spring and push rod.

94E-98E SERIES 7-9

(1)
7. FUEL INJECTION PUMP/GOVERNOR

(3) Parts inspection and measurement

(3-1) Check valve
Replace with a new one as a rule.
Check mainly for deformation and partially
wear.

(3-2) Piston
Check mainly for surface defect and wear.
7 8
(3-3) Springs (piston and check valve) YE0467
Check mainly for surface defect, fatigue and
rust.
7) Check valve
8) Piston

(3-4) Tappet ass’y and push rod

Check mainly for surface defect and wear. if
the push rod outer surface is worn, replace
the whole housing ass’y.

YE0468

Tappet

7-10 94E-98E SERIES

(1)
 7. FUEL INJECTION PUMP/GOVERNOR

7.5 Governor
(1) Components
NOTE: This figure shows the standard RSV governor components. Shapes of some parts are differrent in
the governor for this engine.

YE0469

1) Flyweight 2) Governor housing 3) Governor cover

(2) Disassembly procedure (Reverse the procedure for assembly.)

1. Follow steps and in fuel injection pump disassembly procedure 7.2 (3-2).

(3) Parts inspection and measurement

Generally end disassembly in this stage and wash the parts for inspection.
See that each parts is not worn excessively or play.

94E-98E SERIES 7-11

(1)
7. FUEL INJECTION PUMP/GOVERNOR

7.6 Special service tools for disassembly/assembly

No. Tool name Application Manufacturer’s code and illustration

157926-5110

1 Extractor Flyweight removal

157931-2500

45
35
3
Tappet and cam contact
2 Tappet holder
separation φ2.3

YE0471

157921-0120

3 Tappet insert Pushing tappet up

φ8 233
16

YE0472

157931-6120

18

4 Clamp Tappet removal

256

YE0473

7-12 94E-98E SERIES

(1)
 7. FUEL INJECTION PUMP/GOVERNOR

No. Tool name Application Manufacturer’s code and illustration

157915-0100

φ22
30

5 Wrench Flyweight nut removal

12.7

2.0
YE0474

94E-98E SERIES 7-13

(1)
 8. STARTING MOTOR

8. STARTING MOTOR

8.1 Specifications......................................................................................................................................... 8- 2
8.2 Components .......................................................................................................................................... 8- 3
8.3 Troubleshooting ..................................................................................................................................... 8- 4
8.4 Names of parts and disassembly procedure ......................................................................................... 8- 5
8.5 Inspection and maintenance .................................................................................................................. 8- 9
8.6 Service standards ................................................................................................................................ 8- 15
8.7 Assembly ............................................................................................................................................. 8- 16
8.8 Characteristic test ................................................................................................................................ 8- 18

94E-98E SERIES 8-1

(1)
8. STARTING MOTOR

8.1 Specifications

Manufacturer’s model (Hitachi) — S13-204 S13-205

Code — 129900-77010 129900-77020

Nominal output kW {HP} 2.3 {3.1}

Weight kg 5.5

Revolution direction (as viewed from pinion) — Clockwise

Engagement system — Magnetic shift

Terminal voltage/current V/A 11/140 or less

No-load
Revolution rpm 4,100 or above

Terminal voltage/current V/A 2.5/1,050 or less

Loaded
Torque Nm {kgm} 24.5 {2.5} or above

Clutch system — Overrunning

Pinion projection voltage (at 100°C) V 8.6 or less

Pinion DP or module/number of teeth — M3/9

Difference (O-ring, oil seal) — Dry type (none) Wet type (equipped)

Application — Standard If equipped

8-2 94E-98E SERIES

(1)
 8. STARTING MOTOR

8.2 Components

2 3

13

12

11 5

10 9 8 6

7
YE0475

1) Magnetic switch
2) Shift lever
3) Gear case
4) Oil seal
5) Pinion shaft
6) Bearing retainer
7) O-ring
8) Clutch Ass’y
9) Armature
10) Rear cover
11) Through bolt
12) Brush
13) Field coil

94E-98E SERIES 8-3

(1)
8. STARTING MOTOR

8.3 Troubleshooting

8-4 94E-98E SERIES

(1)
 8. STARTING MOTOR

8.4 Names of parts and disassembly procedure

Disassembling order
(1) Nut M8 (10) Dust cover
(Disconnect the connecting wire.) (11) Shift lever
a See the disassembly drawing. (12) Screw M4 (3)
(2) Screw M4 (2) (13) Bearing retainer
(3) Through bolt M5 (2) (14) Gear case
(4) Rear cover (15) Pinion stopper clip
(5) Brush holder (16) Pinion stopper
(6) Yoke ass’y (17) Return spring
(7) Armature (18) Pinion shaft
(8) Bolt M6 (2) (19) Clutch ass’y
(9) Magnetic switch

Disassembly drawing

YE0477

94E-98E SERIES 8-5

(1)
8. STARTING MOTOR

Disassembly procedure
1) Nut M8
Remove the magnetic switch nut M8 (12 mm),
and disconnect the connecting wire.

YE0478
Fig. 1
a) Connecting wire

2) Screw M4 (2)
3) Through bolt M5 (2)
4) Rear cover
Remove the M4 screw fastening the brush
holder and remove through bolt M5 for rear
cover removal.

YE0479
Fig. 2

5) Brush holder
Pull the brush spring up with the brush spring
puller. On the negative (–) side, bring the brush
spring into contact with the side of the brush for
lifting from the commutator surface. On the posi-
tive (+) side, extract the brush from the brush
holder.

YE0480
Fig. 3

8-6 94E-98E SERIES

(1)
 8. STARTING MOTOR

6) Yoke ass’y
7) Armature
Remove the brush holder. The armature and
yoke ass’y can now be removed.

YE0481

Fig. 4

8) Bolt M6 (2)
9) Magnetic switch
Remove bolt M6 (10 mm), and the magnetic
switch can be removed.

YE0482

Fig. 5

10) Dust cover

11) Shift lever
Take the dust cover out from the gear case. The
shift lever can be removed.

YE0483

Fig. 6

94E-98E SERIES 8-7

(1)
8. STARTING MOTOR

12) Screw M4 (3)

13) Bearing retainer
14) Gear case
Remove Screw M4, and the bearing retainer and
clutch ass’y can be removed.

YE0484
Fig. 7

15) Pinion stopper clip

Remove the bearing retainer at the edge and a
the bearing, and shift the pinion stopper toward
the pinion. Use a plain screwdriver and pry to
remove the pinion stopper clip.
b

YE0485

Fig. 8
a) Pinion stopper clip
b) Plain (straight-edge) screw driver

16) Pinion stopper

17) Return spring
18) Pinion shaft
19) Clutch ass’y
Remove the pinion stopper clip. The pinion
stopper, return spring, pinion shaft and bearing
retainer can be removed.

Disassembly is completed now.

YE0486

Fig. 9

8-8 94E-98E SERIES

(1)
 8. STARTING MOTOR

8.5 Inspection and maintenance

(1) Armature
(a) Commutator outside diameter
Measure the commutator outside diameter
and replace the commutator if the measured
value is less than the limit.

(Unit: mm)
Standard Limit

36.5 35.5

YE0487

Fig. 10

(b) Armature coil continuity test

Check continuity between commutator seg-
ments with a multimeter. Good if continuity 1
exists.

No continuity

(Coil disconnection)
Replace the armature.

YE0488

Fig. 11
1) Multimeter

(c) Armature coil insulation test

Inspect the continuity between a commuta-
1
tor segment and the shaft or core with a
multimeter. Good if no continuity exists.

Continuity exists

(Coil short circuit)

Replace the armature.

YE0489

Fig. 12
1) Multimeter

94E-98E SERIES 8-9

(1)
8. STARTING MOTOR

(d) Armature and commutator runout

Use a dial gauge and measure the armature
core runout and commutator runout. Correct 2
or replace if the limit is exceeded. 1

(Unit: mm)
Standard Limit
Armature 0.03 0.2

Commutator 0.03 0.2

YE0490

Fig. 13
1) Commutator 2) Armature

(e) Commutator surface inspection

If the commutator surface is roughened,
grind with #500 to #600 emery cloth.

YE0491

Fig. 14

(f) Commutator insulation depth

Measure the depth of the insulating material
between commutator segments, and correct
it if it is less than the limit. 3

(Unit: mm) 4
Standard Limit
5 8
0.5 – 0.8 0.2 6

7 9
YE0492

Fig. 15
3) Hack-saw 7) Abnormal
4) Commutator 8) Chamfering
5) Commutator segment 9) Normal
6) Insulating material

8-10 94E-98E SERIES

(1)
 8. STARTING MOTOR

(2) Field coil

(a) Field coil continuity test 1
Check continuity between field coil termi-
nals. Good if continuity exists.

No continuity

(Coil disconnection)
Replace the field coil.

YE0493

Fig. 16
1) Multimeter

(b) Field coil insulation test

Check continuity between field coil terminal 1
and yoke. Good if no continuity exists.

Continuity exists

(Coil short circuit)

Replace the armature.

YE0494

Fig. 17
1) Multimeter

(3) Brush
Measure the length of the brush. Replace with a
good one if the length is less than the limit.

(Unit: mm)
Standard Limit

15 9

YE0495
Fig. 18
2) Brush

94E-98E SERIES 8-11

(1)
8. STARTING MOTOR

(4) Brush holder

(a) Brush holder insulation test
Check the continuity between the brush
holder (+ side) and base (– side) with a mul-
timeter. Good if no continuity exists.

Continuity exists

Insulation defect
1
Replace the brush holder.

YE0496

Fig. 19
1) Multimeter

(b) Brush spring inspection

Inspect the brush spring pressure.
Standard spring pressure

31 – 39 N {3.1 – 3.9 kg}

YE0497

Fig. 20

(5) Magnetic switch

k When the starting motor is wetted with
water, always replace the magnetic switch
with a new even if the function is normal.

(a) Shunt coil continuity test

Check the continuity between the S terminal 1
and the switch body. Good if continuity
exists.

No continuity

Coil disconnection
Replace the magnetic switch.
YE0498

Fig. 21
1) Multimeter

8-12 94E-98E SERIES

(1)
 8. STARTING MOTOR

(b) Series coil continuity test

Check continuity between the S and M ter-
minals. Good if continuity exists.

No continuity

Coil disconnection 1
Replace the magnetic switch.

YE0499
Fig. 22
1) Multimeter

(c) Contact continuity test

Depress the magnetic switch with the 1
plunger at the bottom. Check continuity
between the B and M terminals with a multi-
meter. Good if continuity exists.

No continuity

Contact continuity defect

Replace the magnetic switch.

YE0500

Fig. 23
1) Multimeter

(6) Pinion clutch

(a) Pinion inspection
Manually rotate the pinion. Inspect if it is
rotated smoothly in the driving direction, and
is locked in the opposite direction. Replace
the pinion clutch if abnormal.

YE0501
Fig. 24

94E-98E SERIES 8-13

(1)
8. STARTING MOTOR

(b) Pinion sliding inspection

Check if the pinion slide smoothly in the
axial direction.
If damaged, rusted or heavy in sliding,
repair it.
If grease is applied too much on the pinion
shaft, sliding becomes heavy.

YE0502
Fig. 25

(c) Ball bearing inspection

Rotate the ball bearing while holding the
outer race with fingertips. Inspect if it is
sticking or if there is play.

YE0503

Fig. 26

8-14 94E-98E SERIES

(1)
 8. STARTING MOTOR

8.6 Service standards

Spring force N {kg} 35 {3.6}

Bush
Standard height/wear limit mm 15/9
Magnetic switch resistance, series coil/shunt coil (at 20°C) z 0.27/0.60

Standard diameter/limit diameter mm 36.5/35.5

Difference between maximum

Commutator Repair limit/repair accuracy mm 0.2/0.03
and minimum diameter
Mica undercut depth chips Repair limit/repair accuracy mm 0.2/0.5 – 0.8

Armature front — 6903DDU

Armature rear — 608DDU

Bearing type Nominal number
Pinion front — 6004DDU

Pinion rear — 6904DDU

l dimension (pinion projection length) mm 0.3 – 1.5

94E-98E SERIES 8-15

(1)
8. STARTING MOTOR

8.7 Assembly
The assembly procedure is the reverse of the disassembly procedure, but pay attention to the following
points:

(1) Grease application points

• Gears in the gear case
• Shift lever operating portion
• Pinion sliding portion
• Magnetic switch plunger sliding portion
a Use the specified grease as below table at all points.

Pinion and magnetic switch plunger sliding portions NPCFG-6A

Gears MALTEMP SRL

Shift lever operating portion ALBANIA No.1

(2) Magnetic switch assembly

(a) Install the shift lever on the magnetic switch
with the torsion spring in-between.

YE0504

Fig. 27

(b) For installation on the gear case, install the

magnetic switch with the shift lever on the
gear case after pulling the pinion out. Fix the
magnetic switch by tightening a built-in bolt
M6. Do not forget to install the dust cover
(adjusting shim).

YE0505

Fig. 28

8-16 94E-98E SERIES

(1)
 8. STARTING MOTOR

(3) Pinion projection length

Connect the positive (+) lead from the battery to
terminal S and negative (–) lead to terminal M.
Turn the switch ON and measure the pinion
moving distance l in the thrust direction.
Perform this test within 10 seconds.

Standard

l 0.3 – 1.5 mm

a Before measuring the dimension, pull the

pinion out lightly in the direction of the arrow.

YE0506
Fig. 29

If the measured l dimension is outside the stan-

dard range, either insert or remove the dust 1
cover (adjusting shim 0.5 mm, 0.8 mm) for
adjustment.

YE0507

Fig. 30
1) Dust cover (adjusting shim: 0.5 mm, 0.8 mm)

94E-98E SERIES 8-17

(1)
8. STARTING MOTOR

8.8 Characteristic test

Since the characteristics can be checked roughly by means of a simple no-load test as explained below.
a Complete the test quickly since the rating of the starting motor is 30 seconds.

1. No-load test
Fix the starting motor on a test bench and connect wiring as shown in Fig.31. When the switch is closed, a
current flows in the starting motor, which is rotated at no-load. Measure the current, voltage and number of
revolutions then and check if they satisfy the specified characteristics.

YE0508

Fig. 31
1) Ammeter
2) Voltmeter
3) Battery

8-18 94E-98E SERIES

(1)
 9. ALTERNATOR

9. ALTERNATOR

9.1 Specifications......................................................................................................................................... 9- 2
9.2 Sectional view........................................................................................................................................ 9- 3
9.3 Troubleshooting ..................................................................................................................................... 9- 4
9.4 Parts names and disassembly procedure.............................................................................................. 9- 5
9.5 Inspection and overhaul......................................................................................................................... 9- 8
9.6 Assembly ............................................................................................................................................. 9- 12
9.7 Service standards ................................................................................................................................ 9- 13
9.8 Performance test ................................................................................................................................. 9- 14

94E-98E SERIES 9-1

(1)
9. ALTERNATOR

9.1 Specifications

Manufacturer’s model (Hitachi) — LR140-714

Code — 119836-77200
Rating — Continuous

Battery voltage V 12

Nominal output VxA 12 x 40

Rated revolution rpm 5,000

Operating revolution rpm 1,050 – 12,400

Grounding characteristics — —

Direction of revolution (viewed from pulley) — Clockwise

Weight kg 3.5

Pulley (outside diameter) mm 70

V-belt shape — Type A

9-2 94E-98E SERIES

(1)
 9. ALTERNATOR

9.2 Sectional view

1 2 3

12 6

11

9
10
YE0509

1) Front cover
2) Stator
3) Rotor
4) IC regulator
5) Brush
6) Slip ring
7) Ball bearing
8) Diode
9) Rear cover
10) Through-bolt
11) Ball bearing
12) V-pulley

94E-98E SERIES 9-3

(1)
9. ALTERNATOR

9.3 Troubleshooting

9-4 94E-98E SERIES

(1)
 9. ALTERNATOR

9.4 Parts names and disassembly procedure

Disassembly Procedure e: Refer to the disassembly drawing.
e (1) Through bolt M5 (10) Rear cover
(2) Pulley nut e (11) Lead wire assembly
(3) Pulley assembly e (12) Stator
e (4) Rotor (13) Nut M4
(5) Screw M5 e (14) Fan guide (Disassembly hereafter is
(6) Bearing retainer unnecessary if the diode is faulty.)
(7) Ball bearing e (15) Battery terminal, bolt M5
e (8) Front cover (16) Diode
(9) Nuts M5 and M6 (17) Capacitor
e (18) Brush regulator assembly

Disassembly Drawing

94E-98E SERIES 9-5

(1)
9. ALTERNATOR

Disassembly Procedures
1) Through bolt M5
Remove the M5 through bolt. Increase the tem-
perature at the center of the rear cover by about
20°C using a soldering iron, insert two flat-head
screwdrivers between the front cover and the
stator core and separate the assembly into the
front side (front cover and rotor) and the rear
side (rear cover and stator).
k Be careful not to damage the stator coil with
the edges of the screwdrivers.
YE0512

Fig. 1

2) Pulley nut
3) Pulley assembly
4) Rotor
Fix the rotor in a vice and remove the M15 (22
mm) pulley nut to separate the pulley, front
cover and rotor.
a Dimensions shown in ( ) indicate the spanner
sizes to be used.

YE0513

Fig. 2

5) Screw M4
6) Bearing retainer
7) Ball bearing
8) Front cover
Remove the M5 screw securing the bearing
retainer to separate the bearing retainer, ball
bearing and front cover.

YE0514
Fig. 3

9) Nuts M5 and M6
10) Rear cover
11) Lead wire assembly
Remove the M5 and M6 nuts securing the diode
and IC regulator. Press in the grommet and
lead wire of the lead wire assembly into the hole
in the rear cover to separate the stay and rear
cover.

YE0515

Fig. 4

9-6 94E-98E SERIES

(1)
 9. ALTERNATOR

12) stator
Disconnect soldering of the diode to remove the
stator.

YE0516

Fig. 5

13) Nut M4
14) Fan guide
Remove the M4 nut securing the fan guide to
separate the fan guide.

YE0517

Fig. 6

15) Battery terminal, M5 bolt

16) Diode
17) Capacitor
18) Brush regulator assembly
Remove the M5 bolt and battery terminal. Dis-
connect the diode L-terminal and soldering of
the brush regulator to remove the brush regula-
tor assembly, capacitor and diode.

YE0518

Fig. 7

94E-98E SERIES 9-7

(1)
9. ALTERNATOR

9.5 Inspection and overhaul

(1) Diode
The diode makes the current flow only in the
direction shown in Fig. 8. Check electrical conti- 2
nuity between two terminals (for example, termi-
nals BAT and U) using a tester as shown in Fig.
9 and, if they are continuity, the diode is accept-
able. if not, the diode is damaged. The diode is
acceptable if two terminals are not continuity
1
when the tester is connected in the reverse 3
manner. The diode is damaged if they are conti-
nuity. YE0519
If even a single diode is faulty as a result of the
above measurements, replace the entire diode Fig. 8
assembly. 1) Current flow direction 3) (–) diode
2) (+) diode

Tester leads Tester leads

E terminal E terminal
(+) (–) (+) (–)
U, V and U, V and
W terminals W terminals

(+) — Not continuity (+) — Continuity

(–) Continuity — (–) Not continuity —

Checking (+) diode Checking (–) diode

k Never use a high-voltage insulation ohmmeter

such as a megger for testing. Otherwise, the di- 4
ode may be damaged.

(2) Rotor
(a) Wear limit for slip spring
Measure the outside diameter of the slip
spring. If wear exceeding 1 mm from the
standard size is measured, replace the rotor
assembly.
Standard: 27 mm, Wear limit: 26 mm
(b) Check of slip ring surface
YE0520
Check that the slip ring surface is smooth
and free from contamination by oil, etc. If Fig. 9
the surface is rough, polish using #500 to
#600 emery cloth. If it is dirty, clean using 5
alcohol.

4) Tester
5) Slip ring O.D.

YE0521

Fig. 10

9-8 94E-98E SERIES

(1)
 9. ALTERNATOR

(c) Rotor coil continuity test

Check electrical continuity between slip 1
rings using a tester.

No continuity

Open circuit of rotor coil

Replace the rotor.
Rotor coil resistance at 20°C: 3.45 z

1) Tester
2) Slip ring 2 YE0522
Fig. 11

(d) Rotor coil insulation test 1

Check electrical continuity between the slip
ring and the rotor core or shaft using a
tester.

Continuity exists

Short-circuiting of rotor coil

Replace the rotor.

1) Tester
2) Slip ring 2
YE0523
Fig. 12

(e) Checking ball bearing

Check the rear ball bearing. If rotation is
unsmooth or abnormal noise is generated,
replace the ball bearing.

YE0524

Fig. 13

(3) Stator
3
(a) Stator coil continuity test
Check electrical continuity between two 4
respective terminals using a tester.

No continuity

Open circuit of stator coil

Replace the stator.
Stator coil resistance at 20°C:
0.108 z/phase
Resistance between terminals U and V:
0.216 z YE0525
Fig. 14
3) Tester
4) Stator

94E-98E SERIES 9-9

(1)
9. ALTERNATOR

(b) Stator coil insulation test

Check electrical continuity between one of
1
the stator coil terminals and the stator core
using a tester.

Continuity exists 2
Short-circuiting of rotor coil
Replace the stator.
3

YE0526

Fif. 15
1) Tester
2) Terminal
3) Stator core

(4) Brush
Measure the brush length. If wear exceeds the
limit (6 mm), replace with a new brush holder
assembly. The wear limit line is indicated on the
brush.
Standard: 18 mm, Wear limit: 6 mm
4
Caution on Brush Lead:
(a) Temperature of soldering iron:
300 – 350°C
Always use the non-acidic paste.

YE0527

Fig. 16
4) Wear limit line

9-10 94E-98E SERIES

(1)
 9. ALTERNATOR

(5) Check of IC regulator

Prepare the connection for test setup as shown
in Fig. 17, using a variable resistor, two 12V bat-
teries, an ohmmeter and a voltmeter.
(a) Jigs required
1. Variable resistor (Rv): 0 – 300 z, 12W (1)
2. Resistor (R1): 10 z, 3W (1)
3. Battery (BAT1, BAT2): 12V (2)
4. DC voltmeter (4 measurement points):
0 – 50V, Class 0.5 (1set)

(b) Measurement procedure

(Refer to Fig. 17.)
1. Measure voltage at V1 (BAT1). If the
measured value is between 10V and
13V, the battery is acceptable.
2. Measure voltage at V3 (voltages of
BAT1 + BAT2). If the measured value is
between 20V and 26V, both batteries 1
and 2 are acceptable.
3. Measure voltage at V2 (voltage across
terminals F and E) while gradually
increasing the resistance of the variable
resistor starting from 0V. Check that
there is a point where the V2 voltage
reaches 2.0V or less of the V1 value of
BAT1 measured in 1. above. If no
change occurs, the regulator is faulty.
So, replace it with a new one. YE0528
4. Measure voltage at V4 (Voltage across Fig. 17 Test circuit for IC regulator alone
the intermediate tap of the variable
resistor and E-terminal), with variable
resistor Rv being fixed. If the measured
value is within the specified range, the
regulator is acceptable. If not, the
regulator is faulty. So, replace it with a
new one.

94E-98E SERIES 9-11

(1)
9. ALTERNATOR

9.6 Assembly
While the reassembly procedures are the reverse of the respective disassembly procedures, pay attention to
the following precautions.
(1) For the tightening torque of each screw, see page 9-5, Disassembly drawing.
(2) High-temperature soldering is used for connection between the diode and the stator coil lead, and the diode
and the brush holder.
Work condition: Soldering iron temperature: 300 to 380°C
Connection time: Must be complete within 5 seconds.
Solder used: 1:5 solder (JIS H16A)

(3) Reassembly of the front and rear 1

(a) Since the rear ball bearing is fixed by the
dead stopping method, increase the
temperature at the center of the rear cover
by about 20°C using a soldering iron before
beginning reassembly.

YE0529

1) Pin

(b) Insert the pin from the outside of the rear

cover and press the brush into the brush
holder before reassembling.

(c) After reassembly is complete, remove the

pin by pulling it out. 1

YE0530

1) Pin

9-12 94E-98E SERIES

(1)
 9. ALTERNATOR

9.7 Service standards

Characteristic Unit Standard

Revolution at 13.5 V (cold at 20°C) rpm 1,050 or less

Adjustment voltage V 14.2 – 14.8

Standard temperature slope V /°C –0.01

13.5 V constant output current (hot at 20°C) A / rpm 40 / 5,000 or above

Stator 0.108 (phase)

Coil resistance (at 20°C) z
Rotor 3.45

94E-98E SERIES 9-13

(1)
9. ALTERNATOR

9.8 Performance test

YE0531

Fig. 20 Test Circuits

1) Ammeter 3) Battery 5) Minimum position
2) Variable resistor 4) Voltmeter 6) Lamp

1. The 0.25 z resistor is connected when the battery is discharging.

Measurement Jigs required:
1. Voltmeter : DC voltmeter 0 to 30V, Class 0.5 (1 set)
2. Ammeter : DC ammeter 0 to 100A, Class 1 (1 set)
3. Variable resistor : 0 to 0.25 z, 1kW (1)
4. Resistor : 0.25 z, 25W (1)

(1) Voltage measurement for adjustment

With the test circuits shown in Fig. 20, open SW1 and close SW2, increase the alternator revolution to the
rated speed of 5,000 rpm and measure the voltage.
Adjustment voltage: Acceptable if the measured value is between 14.2 V and 14.8V.

(2) Revolution at 13.5V

With the test circuits shown in Fig. 20, open SW1 and close SW2, gradually increase the alternator revolu-
tion until the voltmeter reads 13.5V and measure the revolution. The measured value is the operating
speed at 13.5V.
Operating speed: Acceptable if the measured value is 1,050 rpm or less.

(3) Output current measurement

With the test circuits shown in Fig. 20, set the variable resistor to the min. position, close SW1 and SW2,
and increase each output of the alternator. Adjust the variable resistor so the the voltmeter reads 13.5V
and measure the current. The measured value is at each output current.

(4) Cautions on performance test

(a) Use thick wires having a min. Cross section of 8 mm2 and max. length of 2.5 m long connecting the
alternator B and battery (+) terminals, and the E and battery (–) terminals.
(b) Use switches having small contact resistances.

9-14 94E-98E SERIES

(1)
 10. SPECIAL SERVICE TOOLS

10. SPECIAL SERVICE TOOLS

10.1 Special tools ........................................................................................................................................ 10- 2

10.2 Measuring instruments ........................................................................................................................ 10- 4

94E-98E SERIES 10-1

(1)
10. SPECIAL SERVICE TOOLS

10.1 Special tools

No. Tool name Applicable model and tool size Illustration

(Unit: mm)
Valve guide tool l1 l2 d1 d2
1
(for extracting valve guide)
20 75 7.5 11

a Locally manufactured
YE0532

(Unit: mm)

Valve guide tool l1 l2 d1 d2

2
(for inserting valve guide) 15 65 14 20

a Locally manufactured
YE0533

(Unit: mm)
Connecting rod bushing
replacer l1 l2 d1 d2
3
(for removal/installation of
connecting rod bushing) 10 100 30 –0.3
–0.6 33 –0.3
–0.6

a Locally manufactured YE0534

Valve spring compressor Code No.

4 (for removal/installation of
valve spring) 129100-92630

YE0535

(Unit: mm)
Valve stem seal inserter
l1 l2 d1 d2
5 (for inserting valve stem
seal) 19 65 16.5 23

a Locally manufactured
YE0536

10-2 94E-98E SERIES

(1)
 10. SPECIAL SERVICE TOOLS

No. Tool name Applicable model and tool size Illustration

Filter wrench
6 (for removal/installation of Available on the market
filter)
YE0537

(Unit: mm)
Camshaft bushing tool l1 l2 d1 d2
7 (for extracting camshaft
bushing) 18 70 50 –0.3
–0.6 53 –0.3
–0.6

a Locally manufactured YE0538

Applicable Applicable
Flex-Hone Code No.
engine model bore (mm)
8 (For re-honing of
cylinder liner) 4D94E 129400-92430 83 – 95

4D98E 129400-92440 89 – 101

YE0539

Code No.

95550-002476
Piston insertion tool
9
(for inserting piston)
a The above piston insertion tool is
applicable to 60 – 125 mm diameter
pistons. YE0540

Piston ring replacer

10 (for removal/installation of Available on the market
piston ring)
YE0541

94E-98E SERIES 10-3

(1)
10. SPECIAL SERVICE TOOLS

10.2 Measuring instruments

No. Instrument name Application Illustration

Measurements of shaft bending, and strain

1 Dial gauge
and gap of surfaces
YE0542

Measurements of narrow or deep portions

2 Test indicator
that cannot be measured by dial gauge
YE0543

For holding the dial gauge when measur-

3 Magnetic stand ing using a dial gauge, standing angles
adjustable

YE0544

For measuring the outside diameters of

4 Micrometer
crankshaft, pistons, piston pins, etc.
YE0545

For measuring the inside diameters of cyl-

5 Cylinder gauge
inder liners, connecting rod metal, etc
YE0546

For measuring outside diameters, depth,

6 Calipers
thickness and width
YE0547

7 Depth micrometer For measuring of valve sink

YE0548

For measuring valve spring inclination and

8 Square
straightness of parts

YE0549

10-4 94E-98E SERIES

(1)
 10. SPECIAL SERVICE TOOLS

No. Instrument name Application Illustration

9 V-block For measuring shaft bend

YE0550

YE0551
For tightening nuts and bolts to the speci-
10 Torque wrench
fied torque

YE0552

For measuring gaps between piston ring

11 Thickness gauge and ring groove, and shaft joints during
assembly
YE0553

12 Cap tester For checking cooling water leakage

YE0554

For checking concentration of antifreeze

13 Battery coolant tester
and the battery electrolyte charge status
YE0555

For measuring injection spray pattern of

14 Nozzle tester
fuel injection nozzle and injection pressure

YE0556

15 Digital thermometer For measuring temperatures

1
1) Probe
YE0557

94E-98E SERIES 10-5

(1)
10. SPECIAL SERVICE TOOLS

No. Instrument name Application Illustration

For measuring revolution by contacting

Contact type
the mortise in the revolving shaft
YE0558

2
For measuring revolution by sensing the
reflecting mark on the outer periphery of
Photoelectric type the revolving shaft
Speedometer

2) Revolving shaft
3) Reflection mark
16 3 YE0559

Measures the revolution regardless of the 4

center or periphery of the revolving object.
Fuel high-pressure
pipe clamp type
4) High-pressure pipe

YE0560

For measuring resistance, voltage and

17 Circuit tester
continuity of electrical circuits

YE0561

For measuring compression pressure

18 Compression gauge kit Code No.

TOL-97190080

YE0562

10-6 94E-98E SERIES

(1)
 11. SERVICE STANDARDS

11. SERVICE STANDARDS

11.1 Engine tuning....................................................................................................................................... 11- 2

11.2 Engine body ......................................................................................................................................... 11- 3
11.3 Lubricating oil system (trochoid pump) ................................................................................................ 11- 7
11.4 Tightening torques for main parts ........................................................................................................ 11- 8

94E-98E SERIES 11-1

(1)
11. SERVICE STANDARDS

11.1 Engine tuning

Reference
No. Inspection item Unit Standard Limit
page
1 Gap at intake/exhaust valve heads mm 0.15 – 0.25 — 3-4

V-belt tension Used part mm 10 – 15 — 3-3

2 Finger pressure:
98N {10kg} New part mm 7–9 — 3-3

MPa
3 Fuel injection pressure 21.57 – 22.55 {220 – 230} — 3-4
{kg/cm2}
degrees
4 Fuel injection timing (FID) 10 – 12 — 3-8
(B.T.D.C)

Specification/Model — 4D94E 4D98E —

2,000 rpm 2,155 – 2,205 3-9

2,200 rpm 2,373 – 2,423 3-9
Max.
2,400 rpm 2,567 – 2,617 3-9

5 No-load revolution 2,500 rpm 2,675 – 2,725 3-9

2,000 rpm 800 or less 3-9

2,200 rpm 800 or less 3-9

Min.
2,400 rpm 800 or less 3-9

2,500 rpm 800 or less 3-9

MPa 2.7±0.1
6 Compression (at 250 rpm) 3.4 ± 0.1{35 ± 1} 2-6
{kg/cm2} {28±1}

7 Top clearance mm 0.737 – 0.869 — —

8 Cooling water capacity l 4.2 (engine only) — 3-2

Lubricating oil capacity Total l 10.2 — 3-2

9
(oil pan) Effective l 4.5 — 3-2

MPa
Max. (in cold state) 0.59 {6.0} or less — —
{kg/cm2}

Lubricating oil MPa

10 At rated output 0.29 – 0.39 {3.0 – 4.0} — —
pressure {kg/cm2}

MPa
At idling 0.06 {0.6} or above — —
{kg/cm2}

MPa
11 Oil pressure switch operating pressure 0.05 {0.5 ± 0.1} — —
{kg/cm2}

12 Thermostat valve opening temperature °C 69.5 – 72.5 — 3-10

13 Themoswitch actuating temperatue °C 107 – 113 — 3-10

11-2 94E-98E SERIES

(1)
 11. SERVICE STANDARDS

11.2 Engine body

(1) Cylinder head
(1-1) Cylinder head

Reference
Inspection item Unit Standard Limit
page
Combustion surface distortion mm Max. 0.05 0.15 4-6
Intake mm 0.5 – 0.7 1.0 4-6
Valve sink
Exhaust mm 0.6 – 0.8 1.1 4-6
Intake mm 1.3 2.0 4-6
Seat width
Valve seat Exhaust mm 2.2 3.0 4-6
Intake Deg. 120 — 4-10
Seat angle
Exhaust Deg. 90 — 4-10
Seat correction angle Deg. 40,
1 2 150 — 4-10

(1-2) Intake/exhaust valve and guide

Reference
Inspection item Unit Standard Limit
page
Valve stem outside diameter mm 7.965 – 7.980 7.915 4-7
Intake Valve guide inside diameter mm 8.015 – 8.030 8.100 4-7
Valve clearance mm 0.035 – 0.065 0.185 4-7
Valve stem outside diameter mm 7.955 – 7.970 7.905 4-7
Exhaust Valve guide inside diameter mm 8.015 – 8.030 8.100 4-7
Valve clearance mm 0.045 – 0.075 0.195 4-7
Valve guide driving-in method — Cold-fitted — 4-11
Valve guide projection from cylinder head mm 14.7 – 15.0 — 4-11
Replacement valve guide inside diameter after insert mm 8.015 – 8.030 — 4-11

(1-3) Valve spring

Reference
Inspection item Unit Standard Limit
Page
Free length mm 47.5 — 4-8
Inclination mm — 1.2 4-8
Load for compressing uneven pitch portion by 1 mm N {kg} 22.1 {2.257} — —

(1-4) Rocker arm and shaft

Reference
Inspection item Unit Standard Limit
page
Rocker arm shaft hole diameter mm 18.50 – 18.52 18.57 4-9
Rocker arm shaft outside diameter mm 18.47 – 18.49 18.44 4-9
Clearance mm 0.01 – 0.05 0.13 4-9

94E-98E SERIES 11-3

(1)
11. SERVICE STANDARDS

(1-5) Push rod

Reference
Inspection item Unit Standard Limit
page
Bend mm — 0.03 4-9

(2) Gear Train and Camshaft

(2-1) Camshaft

Reference
Inspection item Unit Standard Limit
page
End play mm 0.05 – 0.20 0.30 4-14
Bending (1/2 the dial gauge reading) mm 0 – 0.02 0.05 4-15
Cam height mm 42.435 – 42.565 42.185 4-15
Camshaft outside diameter mm 49.925 – 49.950 49.890 4-15
Gear side Bushing inside diameter mm 49.990 – 50.055 50.130 4-15
Clearance mm 0.040 – 0.130 0.240 4-15
Camshaft outside diameter mm 49.910 – 49.935 49.875 4-15
Intermediate Block inside diameter mm 50.000 – 50.025 50.100 4-15
Clearance mm 0.065 – 0.115 0.225 4-15
Camshaft outside diameter mm 49.925 – 49.950 49.890 4-15
Flywheel side Block inside diameter mm 50.000 – 50.025 50.100 4-15
Clearance mm 0.050 – 0.100 0.210 4-15

(2-2) Idle gear shaft and bushing

Reference
Inspection item Unit Standard Limit
page
Shaft outside diameter mm 45.950 – 49.975 45.900 4-16
Bushing inside diameter mm 46.000 – 46.025 46.075 4-16
Clearance mm 0.025 – 0.075 0.175 4-16

(2-3) Backlash of each gear

Reference
Inspection item Unit Standard Limit
page
Crank gear, cam gear, idle gear, fuel injection pump
mm 0.08 – 0.14 0.16 4-13
gear and PTO gear
Lubricating pump gear mm 0.09 – 0.15 0.17 4-13

11-4 94E-98E SERIES

(1)
 11. SERVICE STANDARDS

(3) Cylinder block

(3-1) Cylinder block

Reference
Inspection item Unit Standard Limit
page
4D94E mm 94.000 – 94.030 94.130 4-21
Inner diameter
4D98E mm 98.000 – 98.030 98.130 4-21
Cylinder bore
Roundness mm 0.01 or less 0.03 4-21
Cylindricity mm 0.01 or less 0.03 4-21

(3-2) Crankshaft

Reference
Inspection item Unit Standard Limit
page
Bending (1/2 the dial gauge reading) mm — 0.02 4-22
Pin outside diameter mm 57.952 – 57.962 57.902 4-23
Metal thickness mm 1.492 – 1.500 — 4-23
Crank pin
US 0.25 mm mm 1.617 – 1.625 — 4-23
Clearance mm 0.038 – 0.074 0.150 4-23
Journal outside diameter mm 64.952 – 64.962 64.902 4-23
Metal thickness mm 1.995 – 2.010 — 4-23
Crank journal
US 0.25 mm mm 2.125 – 2.130 — 4-23
Clearance mm 0.038 – 0.068 0.150 4-23

(3-3) Thrust bearing

Reference
Inspection item Unit Standard Limit
page
Crankshaft end play mm 0.11 – 0.21 — 4-19
mm 1.930 – 1.980 1.850 4-24
Thrust bearing thickness
OS 0.25 mm mm 2.055 – 2.105 — 4-24

94E-98E SERIES 11-5

(1)
11. SERVICE STANDARDS

(3-4) Piston and ring

Reference
Inspection item Unit Standard Limit
page
4D94E mm 93.945 – 93.955 93.900 4-24
OS 0.25 mm mm 94.195 – 94.205 — 4-24

Piston outside diam- OS 0.50 mm mm 94.445 – 94.455 — 4-24

eter 4D98E mm 97.945 – 97.955 97.900 4-24
OS 0.25 mm mm 98.195 – 98.205 — 4-24
OS 0.50 mm mm 98.445 – 98.455 — 4-24
Clearance with cylinder bore
Note) Measure at 22 mm above the piston bottom mm 0.050 – 0.080 0.120 4-24
face in vertical direction to the piston pin.
Piston outside diameter mm 29.989 – 30.000 29.959 4-25
Piston pin Hole inside diameter mm 30.000 – 30.009 30.039 4-25
Clearance mm 0.000 – 0.020 0.080 4-25
Piston ring groove width mm 2.040 – 2.060 — 4-25
Piston ring width mm 1.940 – 1.960 1.920 4-25
Top ring
Piston side clearance mm 0.080 – 0.120 — 4-25
Piston end clearance mm 0.250 – 0.450 0.540 4-25
Piston ring groove width mm 2.080 – 2.095 2.195 4-25
Piston ring width mm 1.970 – 1.990 1.950 4-25
Second ring
Piston side clearance mm 0.090 – 0.125 0.245 4-25
Piston end clearance mm 0.450 – 0.650 0.730 4-25
Piston ring groove width mm 3.015 – 3.030 3.130 4-25
Piston ring width mm 2.970 – 2.990 2.950 4-25
Oil ring
Piston side clearance mm 0.025 – 0.060 0.180 4-25
Piston end clearance mm 0.250 – 0.450 0.550 4-25

11-6 94E-98E SERIES

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 11. SERVICE STANDARDS

(3-5) Connecting rod

Reference
Inspection item Unit Standard Limit
page
Thrust clearance mm 0.20 – 0.40 — 4-18
Bushing inside diameter mm 30.025 – 30.038 30.068 4-26
Small end of
Piston pin outside diameter mm 29.987 – 30.000 29.959 4-26
connecting rod
Clearance mm 0.025 – 0.051 0.109 4-26

(3-6) Tappet

Reference
Inspection item Unit Standard Limit
page
Tappet stem outside diameter mm 11.975 – 11.990 11.955 4-27
Tappet hole (block) inside diameter mm 12.000 – 12.018 12.038 4-27
Clearance mm 0.010 – 0.043 0.083 4-27

11.3 Lubricating oil system (trochoid pump)

Reference
Inspection item Unit Standard Limit
page
Clearance between outer rotor and gear case mm 0.100 – 0.155 0.25 5-4
Side clearance between outer rotor and gear case mm 0.05 – 0.10 0.15 5-4
Shaft outer diameter mm 12.955 – 12.970 12.945 5-4
Rotor shaft and
Bearing inside diameter mm 12.980 – 13.020 13.050 5-4
gear case
Clearance mm 0.010 – 0.065 0.105 5-4

94E-98E SERIES 11-7

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11. SERVICE STANDARDS

11.4 Tightening torques for main parts

Nm {kgm}
Nominal Reference
Tightening position Tightening torque
size page
Thermostat case M8 22.5 – 28.4 {2.3 – 2.9} 6-3
Intake manifold M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Exhaust manifold M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Cylinder head Bonnet M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Valve arm support M10 44.1 – 53.9 {4.5 – 5.5} 4-3
(*1) Fuel injection nozzle M6 6.9 – 8.8 {0.7 – 0.9} 4-3
Engine hoisting hook M8 22.5 – 28.4 {2.3 – 2.9} 4-3
(*2) Cylinder head M11 102. 9 – 112.7 {10.5 – 11.5} 4-5
Gear case M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Idle gear shaft M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Camshaft thrust bearing M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Oil pan M8 22.5 – 28.4 {2.3 – 2.9} 4-16
M10 44.1 – 53.9 {4.5 – 5.5}
Cylinder block Flywheel housing 4-18
M8 22.5 – 28.4 {2.3 – 2.9}
(*2) Bearing cap M11 107. 8 – 117.6 {11.0 – 12.0} 4-19
Lubricating oil suction pipe M8 22.5 – 28.4 {2.3 – 2.9} 4-17
PTO lubrication pipe M8 12.7 – 16.7 {1.3 – 1.7} 4-12
Fuel injection pump inlet pipe M8 12.7 – 16.7 {1.3 – 1.7} 4-12
Fuel injection pump rear stay M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Cooling water pump M8 17.6 – 22.5 {1.8 – 2.3} 6-3
Alternator M10 44.1 – 53.9 {4.5 – 5.5} 4-3
Gear case cover M8 17.6 – 22.5 {1.8 – 2.3} 4-12
Fuel injection pump M10 34.3 – 44.1 {3.5 – 4.5} 4-12
Gear case Oil pan M8 17.6 – 22.5 {1.8 – 2.3} 4-19
Lubricating oil pump ass’y M8 17.6 – 22.5 {1.8 – 2.3} 5-3
Fuel injection pump drive gear
M8 17.6 – 22.5 {1.8 – 2.3} 4-12
cover
PTO Lubrication pipe M8 12.7 – 16.7 {1.3 – 1.7} 4-12
(*2) Flywheel M14 186. 2 – 205.8 {19 – 21} 4-12
Crankshaft
(*2) Crankshaft pulley M14 107. 8 – 127.4 {11 – 13} 4-13
Connecting rod (*2) Connecting rod bolt M10 53.9 – 58.8 {5.5 – 6.0} 4-18
Mounting flange Starting motor M12 78.4 – 98.0 {8.0 – 10.0} 4-12
Main bearing cap Lubricating oil suction pipe stay M8 22.5 – 28.4 {2.3 – 2.9} 4-17
Intake manifold Fuel filter M10 34.3 – 44.1 {3.5 – 4.5} 4-3

11-8 94E-98E SERIES

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 11. SERVICE STANDARDS

Nm {kgm}
Nominal Reference
Tightening position Tightening torque
size page
Cooling water
Cooling fan M8 17.6 – 22.5 {1.8 – 2.3} 4-3
pump
Fuel injection pipe M12 19.6 – 24.5 {2.0 – 2.5} 4-3
Delivery valve holder — 58.8 – 68.6 {6.0 – 7.0} 7-3
(*1) Drive gear M14 83.3 – 93.1 {8.5 – 9.5} 4-13
Fuel pipe (inlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-3
Fuel injection pump
Fuel pipe (return) M14 19.6 – 24.5 {2.0 – 2.5} 7-3
Fuel feed pump M6 7.8 – 9.4 {0.8 – 0.96} 7-3
Oil inlet pipe M10 9.8 – 12.7 {1.0 – 1.3} 4-12
Rear stay M10 44.1 – 53.9 {4.5 – 5.5} 4-12

Fuel injection noz- Fuel injection pipe M12 19.6 – 24.5 {2.0 – 2.5} 4-3
zle Nozzle holder — 39.2 – 44.1 {4.0 – 4.5} 3-5
Fuel pipe (inlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-8
Fuel pipe (outlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-8
Fuel feed pump
Priming pump M16 39.2 – 44.1 {4.0 – 4.5} 7-8
Plug M26 78.4 – 88.2 {8.0 – 9.0} 7-8
Fuel pipe M12 24.5 – 34.3 {2.5 – 3.5} 4-3
Fuel filter
Fuel return pipe M14 39.2 – 44.1 {4.0 – 4.5} 4-3
Alternator Stay M8 22.5 – 28.4 {2.3 – 2.9} 4-3

Marked (*1): Important bolt

(*2): Apply lubricating oil.

94E-98E SERIES 11-9

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 20. EPA CERTIFIED ENGINE

20. EPA CERTIFIED ENGINE

20.1 Applicable machine, serial number (EPA certified engine) .................................................................. 20- 2

94E-98E SERIES 20-1

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20. EPA CERTIFIED ENGINE

20.1 Applicable machine, serial number (EPA certified engine)

Engine Machine model Machine Serial No. Engine output Remarks

(kW{HP}/rpm)
D20A-7
4D94E-1AB 78604 and up 29.4 {39.4}/2,450
D20P-7

D20PL-7
4D94E-1AB 62454 and up 29.4 {39.4}/2,450
D20PLL-7

D20S-7
4D94E-1AB 61132 and up 29.4 {39.4}/2,450
D20Q-7

D21A-7
4D94E-1AH 78604 and up 29.4 {39.4}/2,450
D21P-7

4D94E-1AH D21PL-7 62454 and up 29.4 {39.4}/2,450

D21S-7
4D94E-1AH 61132 and up 29.4 {39.4}/2,450
D21Q-7

D21A-7T
4D98E-1AD 78604 and up 36.78 {49.3}/2,450
D21P-7T

4D98E-1D PG75 1001 and up 44 {59.2}/2,000

20-2 94E-98E SERIES

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