99089-40100 00

SERVICE MANUAL December 2015
Pub. No. 99089-40100
1COVER
for Eastern Refinery Limited.

Foreword
This service manual describes the maintenance and adjustment procedures, and specifi-
cations for Mitsubishi diesel engines.
To maintain the performance of the engine for many years and to ensure safe operation,
it is important to use the engine correctly and conduct scheduled inspection and mainte-
nance, and it may also be necessary to take appropriate measures which involve disassem-
bly, inspection, repair and assembly works of the engine and engine parts.
Read through this manual carefully and understand the work procedures fully before dis-
assembling, inspecting, repairing or assembling the engine.
The contents of this manual are based on the engine model produced at the time of publi-
cation. Please note that the contents of this manual may change due to improvements made
thereafter.
99089-40100
I
Foreword
HOW TO USE THIS MANUAL

This service manual consists of several chapters, which will give you quick references to specifications, maintenance standards,
adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi diesel
engines.
A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a detailed
table of contents at the beginning of each chapter.
Regarding the procedures for operation and scheduled maintenance of the engine, refer to the Operation and Maintenance Man-
ual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and func-
tion of the engine are described in the relevant training manuals.
If you have an inquiry, please check the engine model and serial number, and contact our service department.
Brief summary of the system used in compiling this service manual:

(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indica-
tion of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text. They
are also collectively indicated in the Chapter 2.
(4) The tightening torque with engine oil applied on the thread is specified as [Wet]. Unless otherwise specified, the tightening
torque is of dry condition.
(5) In this manual, important safety or other cautionary instructions are emphasized with the following head marks.
Indicates an immediately hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
NOTE: Emphasizes important matter, or indicates information useful for operation or maintenance
of the engine.
II 99089-40100
Foreword
Terms used in this manual

Nominal value
means the basic nominal size of a part to be measured.
Standard value
means the quantitative requirement for dimension of a part, clearance between parts or standard performance of engine. The
values are rounded off for the inspection job, and do not necessarily conform to the design values.
Limit value
means the value, which the measured value reaches, the part needs repair or replacement with a new one.
Abbreviations and Standards

BTDC: Before Top Dead Center
ATDC: After Top Dead Center
BBDC: Before Bottom Dead Center
ABDC: After Bottom Dead Center
TIR: Total Indicator Reading
API: American Petroleum Institute
ASTM: American Society for Testing and Materials
JIS: Japanese Industrial Standards
LLC: Long Life Coolant
MIL: Military Specifications and Standards (U.S.A.)
MSDS: Material Safety Data Sheet
SAE: Society of Automotive Engineers (U.S.A.)
P/N: Part Number
Unit of Measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in { } and
U.S. customary values are in [ ]. For the conversion, the following rates are used.
Pressure: 1 MPa = 10.197 kgf/cm2
Torque: 1 N•m = 0.10197 kgf•m
Force: 1 N = 0.10197 kgf
Output power: 1 kW = 1.341 HP = 1.3596 PS
Pressure (mercury column): 1 kPa = 0.7 cmHg
Pressure (water column): 1 kPa = 10.197 cmH2O (cmAq)
Rotational speed: 1 min-1 = 1 rpm
99089-40100
III
Foreword
Safety Cautions
Fire and Explosion Protection
Keep Flames Away Be Alert for Leaking Fuel, Oil, or Exhaust

Do not use flames near the engine (in Gas
the engine room). The flame is dan- If any fuel, oil or exhaust gas leakage is found, imme-
gerous as it ignites combustibles and diately take corrective measures to stop it. Such leak-
cause a fire. Wipe off spilled fuel, oil ages, if left uncorrected, can cause fuel or engine oil to
and LLC immediately and thoroughly. reach hot engine surfaces or hot exhaust gas to con-
Spilled fuel, oil and LLC may ignite and cause a fire. tact flammable material, may results in a fire, personal
Store the fuel and engine oil in a well ventilated area. injury and damage to the equipment.
Make sure that the fuel and engine oil container caps
Use Explosion-Proof Light
are tightly fastened.
When inspecting fuel, engine oil, coolant, battery elec-
Tidy Up Around the Engine trolyte, etc., use an explosion-proof light. If the lighting
Do not place combustible or explosive material, such is not an explosion-proof type, it may ignite and cause
as fuel, engine oil, LLC or explosive powder near the an explosion.
engine. Such substances can cause a fire or explo-
Prevention of Electric Short Circuit
sion. Thoroughly remove dust, dirt, and other foreign
Avoid inspecting or servicing the electrical system with
material accumulated on the engine and the area
the battery cable connected to the battery. Otherwise,
around the engine. Such material can cause a fire or
a fire could result from a short circuit. Be sure to dis-
the engine to overheat. In particular, clean the top sur-
connect the battery cable from the negative (-) termi-
face of the battery thoroughly. Dust can cause a short
nal before starting work. A loose terminal and a
circuit. Always place the engine at a position at least 1
damaged cable or wire may result in a short circuit and
m [3.28 ft.] apart from buildings and other facilities to
a fire. Inspect, and if any defect is found, repair or
prevent a possible fire caused by engine heat.
replace it before starting work.
Do Not Open Side Covers Until Engine
Keep Fire Extinguishers and First-Aid Kit
Cools
Handy
Do not try to open the side cover of crankcase before
Keep fire extinguishers handy, and
the engine cools down. Wait at least 10 minutes after
become familiar with their usage.
stopping the engine. Opening the cover when the
Keep a first-aid kit at the designated
engine is hot allows fresh air to flow into the crank-
place to be ready for use in an emer-
case, which can cause oil mist to ignite and explode.
gency. Make counteract procedures
against a fire or an accident. Provide the contact per-
son and means of communication in case of emer-
gency.
IV 99089-40100
Foreword
Stay Away From Rotating and Moving Parts
Install Protective Covers Over Rotating Lockout and Tagout

Parts After Inspection and Maintenance Be sure to lockout and tagout before starting inspec-
Work tion and maintenance. Lockout and tagout are effec-

tive methods of cutting off machines and equipment
Check the covers over engine rotating
from energy sources. To accomplish the lockout/
parts for correct installation. Repair
tagout, remove the starter switch key, set the battery
any damaged or loosed covers. Never
switch to the OFF position and attach a DO NOT RUN
remove the protective covers around
or equivalent caution tag to the starter switch. The
rotating parts during operation. When
starter switch key must be kept by the person who per-
the engine is coupled to a radiator or other equipment,
forms inspection and maintenance work. In the case of
install protective covers over the exposed connecting
air starting engine, close the air tank valve and show a
belt and coupling.
"DO NOT OPEN" tag or the like.
Check Work Area for Safety Before Starting
Be Sure to Stop Engine Before Inspection/
Before starting the engine, make sure that no one is
near the engine and that tools are not left on or near Maintenance
the engine. Verbally notify persons within the immedi- Be sure to stop the engine before proceeding to
ate area when starting the engine. When the starter inspection and maintenance work. Never try to make
device is tagged with the warning sign saying DO NOT adjustments on the engine parts while the engine is
RUN, never start the engine. running. Rotating parts such as belt can reel in your
body and cause serious injuries.
Stay Away From Moving Parts During Oper-
ation Always Put Turning Tool Back in Place After
Keep away from the rotating parts Use

during operation. Do not leave any Be sure to remove the turning tool used for inspection
objects that may get caught in rotating and maintenance work. Make sure to pull back the
parts. If clothes or a tool gets caught turning gear to the engine running position before
in rotating parts, serious injury will starting the engine. If the engine is started with a turn-
result. ing tool inserted or left in the turning condition, it can

not only cause a damage to the engine, but also lead
to a personal injury.
99089-40100
V
Foreword
Prevention of Exhaust Gas Poi- Fall Prevention

soning
Lift Engine Carefully
Pay Attention to Ventilation When Operat- Use slings or wire ropes strong
ing Engine enough to lift the load considering the
If the engine is installed in an engine weight. To lift the engine,
enclosed area, and the exhaust gas is attach the proper slings to the lifting
ducted outside, make sure that duct hangers prepared on the engine. To
joints are free from gas leak. When lift the engine, keep the engine in a
the engine is used as a portable gen- well-balanced position, thinking carefully of the engine
erator, do not operate in a poorly ventilated place such center of gravity.
as a room, warehouse and tunnel or near shields. The hangers prepared on the engine are designed for
When the engine must be operated ina room, duct the lifting the weight of engine only. In the case where the
exhaust gas and provide enough ventilation. Pay generator, marine gear, and others are installed to the
attention not to blow the exhaust gas to the animals engine, consider that the additional weight will not
and plants in the surrounding area. Exhaust gas from affect the hangers of the engine.
the engine sometimes contains harmful components. Keep the angle formed by slings attached to hangers
Operating the engine in an ill-ventilated area can within 60°. If the angle exceeds this limit, excessive
cause gas poisoning. load may be applied to the hangers and damage the
hangers. If the wire rope contacts the engine part
Prevention of Hearing Loss
directly, place a cloth or other soft pad to avoid dam-
age to the part and wire rope. Remove the engine part
Wear Ear Plugs
if necessary.
Always wear ear plugs when entering
the machine room (engine room).
Do Not Climb Onto the Engine
Combustion sound and mechanical Do not climb onto the engine, nor step on any engine
noise of engine can cause hearing parts on the engine sides. To work on parts located
loss. high on the engine, use a ladder, footing, and others to

prevent from slipping and falling. Climbing onto the
engine may result in engine part damage and your
injury by falling down.
Always Prepare a Stable Footing

When working on the upper part of
the engine and other hard-to-reach
places, use a stable footing. Stand-
ing on an old footstool or parts box
may result in personal injury. Do not
put any unnecessary objects on the footing.
VI 99089-40100
Foreword
Be Careful When Handling Fuel, Burn Protection

Engine Oil or Coolant
Do Not Touch the Engine During or Immedi-
Use Specified Fuel, Engine Oil and Coolant ately After Operation
Only Do not touch any parts of the engine
Use the fuel, oil and coolant specified in this manual during or immediately after operation.
only, and handle them carefully. Use of material other You can get burned. Before starting
than the specified one, or improper handling may the maintenance and inspection work,
cause various engine defects and malfunctions. Get check the water temperature meter to make sure that
the MSDS issued from the fuel, oil and coolant suppli- the engine is cooled down.
ers, and follow the directions in the MSDS for proper Be Careful to Open and Close the Radiator
handling. Cap
Be Careful with Coolant Never open the radiator cap while the engine is run-
When handling coolant, wear rubber gloves and a pro- ning or immediately after the engine stops. Stop the
tective face mask. If the coolant contacts your skin, or engine and give a sufficient time to allow the coolant to
get into your eyes or mouth, it may cause injury of skin cool down before opening the cap. When opening the
or eyes, or poisoning. If coolant is accidentally swal- radiator cap, slowly open the cap so as to release
lowed, induce vomiting immediately and seek medical internal pressure. To prevent hot steam scald, wear
attention. If coolant enters your eyes, flush them thick rubber gloves, or cover the cap with a cloth.
immediately with plenty of water and seek medical When closing the radiator cap, tightly close the cap.
attention. If coolant contacts your skin or clothing, Do not open the radiator cap during engine running or
wash it away immediately with plenty of water. Keep immediately after engine stop. Otherwise hot steam
flames away from coolant. Coolant can catch flames and coolant gush out and can cause burns.
and cause a fire. Drained coolant is a hazardous mate- Refill Coolant Only After the Coolant Tem-
rial. Do not discard it in an unauthorized procedure.
perature Dropped
Obey the applicable laws and regulations to dispose of
Refill the coolant after the coolant temperature drops
drained coolant.
to a room temperature. Replacement job immediately
Proper Procedure to Discard Waste Oil and after the engine stop may cause burns.
Coolant Do Not Remove Heat Shields
Do not dispose of waste engine oil or coolant in an
The exhaust system, which becomes extremely hot
unauthorized procedure. Such a way of disposal is
while the engine is running, is provided with various
strictly prohibited by laws and regulations. Discard
heat shields. Never remove the heat shields. If any of
waste oil, coolant and other environmentally hazard-
these heat shields were inevitably removed for the
ous waste in accordance with the applicable laws and
inspection and maintenance, be sure to install them
regulations.
after the work.
Burn Prevention When Changing Oil

Wear gloves when draining oil or changing oil filters. If
your skin contacts hot oil or hot parts, you get burn
injury.
99089-40100
VII
Foreword
Battery Safety Precautions When Abnormality Occurs
Be Careful When Handling Battery Do Not Add Coolant Immediately After a

Never use flames or generate Sudden Stop Due to Overheating
sparks near the battery. The bat- If the engine stops suddenly due to overheating, or
tery gives off highly flammable you suddenly stop the engine by any reason, do not
hydrogen gas and oxygen gas. add coolant immediately. If coolant is added immedi-
Any flame or spark near a battery ately, parts such as cylinder heads can be damaged
may cause an explosion.
due to the sudden drop of temperature. Add coolant
Do not use the battery if its fluid level is below the
slowly after the engine becomes cool.
lower limit line. Wrong use of the battery may result
in an explosion. Be Careful When Starting After an Abnor-
Do not short the battery terminals with a tool or other mal Stop
metal object. If the engine stops abnormally, do not restart the
When disconnecting battery cables, always remove engine immediately after the stopping. If the engine
the negative (-) terminal first. When reconnecting the stops or is stopped, inspect the engine to clarify the
cables, always connect the positive (+) terminal first. cause of the defect and correct the cause before
Charge the battery in a well-ventilated area with all
restarting. If the engine is kept operating in such a
battery cables removed.
condition, it can result in serious engine failure.
Make sure the cable clamps are securely fastened to
the battery terminals. A loose terminal can cause When the Engine Oil Pressure Decreases,
sparks that may result in an explosion. Stop the Engine Immediately
Before servicing electrical components or conducting If the engine oil pressure drops significantly, stop the
electric welding, set the battery switch to the [Open/ engine immediately, and inspect the lubrication sys-
OFF] position or disconnect the cable from the nega- tem to find the cause. Continuous engine operation
tive (-) battery terminal to cut off the electrical cur- with low oil pressure may cause bearings and other
rent.
parts to seize.
Electrolyte (battery fluid) contains dilute sulfuric acid.
Careless handling of the battery may lead to the loss
Stop the Engine Immediately When the Belt
of sight and/or skin burns. Also, do not swallow bat- Break
tery fluid. If the belt breaks, stop the engine immediately. Contin-
Wear protective goggles and rubber gloves when uous engine operation with the broken belt can cause
working with the battery (such as adding water or the engine to overheat. Steam of boiled coolant may
charging). gush out from the reserve tank or radiator, and results
If battery electrolyte is spilled onto the skin or cloth- in burns.
ing, immediately wash it away with lots of water. Use
soap to clean thoroughly.
Battery fluid can make you blind if splash into your
eyes. Immediately flush it away with plenty of clean
water, and seek immediate medical attention.
If battery fluid is accidentally swallowed, gargle with
plenty of water, then drink lots of water, and seek
immediate medical attention.
VIII 99089-40100
Foreword
Other Precautions
Do Not Tamper Engine Break-in

If tampered, the warranty is totally void even in the To break-in a new engine or an overhauled engine,
warranty period. Tampering with the engine can not operate the engine at a speed lower than the rated
only damage the engine but also may lead to personal speed in a light load condition during the first 50 hours
injury. of operation. Operating a new engine or an overhauled
Performance of Pre-Operation Inspection engine in a severe condition during the break-in period
shortens the service life of the engine.
and Periodic Inspections
Conduct the daily inspection and periodic inspection/ Warming Up Engine First
maintenance as described in this manual. After starting the engine, run the engine at a low idling
Failure to conduct the specified inspections may cause speed for warming-up, Start the work after the coolant
various engine problems, damage to parts, and a seri- temperature is raised. Warm-up operation circulates
ous accident. lubricant in the engine, and works for the longer ser-
vice life and economical operation. Do not continue
Wear Proper Work Clothing and Protective
the warm-up operation for a longer time than neces-
Gears
sary. Long warm-up operation causes carbon deposits
Wear a hard hat, a face shield, safety shoes, a dust
in the cylinders, and may lead to incomplete combus-
mask, gloves, ear plugs and other protective gears as
tion.
needed. When using compressed air, wear ear plugs,
safety goggles, a hard hat, gloves and other neces-
Do Not Operate the Engine in an Over-
sary protective gears. Works without wearing proper loaded Condition
protective gears may result in serious injury. If the engine shows an overloaded condition such as
black exhaust smoke, reduce the load immediately to
Never Break the Seals
an appropriate load condition. Overloading causes not
To ensure the proper engine operation, the fuel injec-
only high fuel consumption but also excessive carbon
tion pump, governor, handle and fuel control link are
deposits inside the engine. Carbon deposits cause
provided with seals that protect the fuel injection vol-
various problems and will shorten the service life of the
ume and rotation speed settings against tampering. If
engine.
the engine is operated with the seal tampered, no
guarantee will be provided. The defects shown below Cool Down the Engine Before Stopping
may occur if the seal is tampered. Cool down the engine at a low idling for five to six min-
Rapid wear of moving and rotating parts utes before stopping it. Stopping the engine immedi-
Failures such as seizure and damage of engine parts ately after a high-load operation will cause local heat
Sudden increase of fuel and lubricating oil consump- up of engine parts and shorten the service life of the
tion engine. During the cooling operation, check the engine
Poor engine performance due to improper balance for abnormalities.
between fuel injection volume and governor control,
or a serious accident due to overrunning of the
engine
Check the Engine After Operation
After the engine operation, check each part of engine
once again. If any defect is found, correct immediately.
99089-40100
IX
Foreword
Prohibition of Continuous Low-Load Opera- Obey Safety Rules at Work Site

tion Obey the safety rules established at the workplace
Low load continuous operation (less than 30%) must when operating and maintaining the engine. Do not
be limited within one hour. Long warm-up operation operate the engine if you are in bad health. Consult
causes carbon deposits in the cylinders, and may lead your supervisor about your condition. Operation of the
to incomplete combustion. Also, after a continuous low engine with decreased attention may cause improper
load operation, run the engine at a load of 50% or operation and results in an accident. When working in
higher for 30 minutes or more to prevent carbon from a team of two or more people, use specified hand sig-
accumulating. nals to communicate among workers.
Do Not Splash Water on Engine Use Proper Tools for Maintenance Work
Use care to protect engine from water such as rain Always keep in mind to select most appropriate tools
entering through the air inlet or exhaust openings. Do for the work, and use them correctly. If a tool is dam-
not wash the engine while it is running. Cleaning fluid aged, replace it with a new one.
or water can be sucked into the engine. Starting the Engine Transportation Precautions
engine with water inside the combustion chamber can To road-transport the engine, consider the engine
cause the water hammering, and may result in engine weight, width and height, and obey applicable laws
inner parts damage and serious accident. and regulations such as road traffic laws, vehicle road
Air cleaner or acts and vehicle restriction ordinances.
Pre-cleaner is to be properly maintained Pay Attention to Engine Room Ventilation

With foreign material in the intake air, excessive wear Always keep the engine room well-ventilated. Insuffi-
of the engine can result. Worn parts produce many cient intake air amount of the engine can cause an
problems such as increase of oil consumption, increase in the engine temperature, and could result in
decrease of output and starting difficulties. For effec- a decrease in the output power and poor performance.
tive removal of dust from intake air, maintain the air It is highly recommended to calculate the required
cleaner/pre-cleaner according to the following instruc- amount of air supply to the engine and install an ade-
tions. quate ventilation system before installing the engine.
Never perform maintenance of the air cleaner or pre- Do Not Touch High-Pressure Fuel Spray
cleaner during operation. Foreign material enters the
Do not touch fuel jet leaked or sprayed from the high
turbocharger and may result in a serious failure.
pressure injection pipe. Fuel in the fuel injection pipe is
When removing the air cleaner or pre-cleaner, be
under high pressure and if the fuel impinges your skin,
careful to prevent dust and foreign material collected
it goes through the skin and can cause serious injury.
on the cleaner from entering the engine. After
removing the air cleaner or pre-cleaner, immediately
cover the opening (inlet port of engine or turbo-
charger silencer) with plastic sheet or similar means
to prevent foreign materials from entering the
engine.
An air cleaner with a dust indicator gives an alarm
when it is clogged. Conduct the maintenance when
the alarm is given.
X 99089-40100
Foreword
Warning Labels
Maintenance of Warning Labels

Make sure all warning/caution labels are legible.
Clean or replace the warning or caution label when the description or illustration is not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvent, gasoline or other
chemicals to prevent the label from fading and peering.
Replace a damaged or missing label with a new one.
If any engine part stuck with a warning label is replaced with a new one, attach a new identical warning label to the
new part.
To get new warning labels, contact your MHI dealer.
Common Warning Labels
99089-40100
XI
Foreword
Points on Disassembling and Assembling

This service manual contains the recommended practices to Points on Assembling
service the engine. The manual also contains dedicated spe-  Wash all engine parts, except such parts as oil seals, O-
cial tools made for the work, and the basic safety cautions to rings and rubber seats, in cleaning oil, and dry them with
obey when working. Note that this manual does not cover compressed air.
all potential hazards that could occur during maintenance,  Use correct tools and instruments.
inspection and service works of the engine. Use only high-quality lubricating oil and grease of the
appropriate type. Be sure to apply oil, grease or adhesive
When working on the engine, follow the related instructions
to specified surfaces.
in this manual and also pay attention to the following:
Use a torque wrench to tighten parts correctly when their
Points on Disassembling tightening torques are specified. Refer to "Tightening
 Use correct tools and instruments. Otherwise, serious
torque table."
damage or accident may result.
Replace gaskets, packings and O-rings with new ones.
Do not use jack bolts having sharp edge, as they may cause
Apply adhesive as required. Do not apply adhesive too
damage to the surface.
much.
Use a footing or workbench to place disassembled parts as
Use protective gloves when you touch overheated or fro-
required, and obey the disassembly procedure in this
zen parts. Touching such a part with a bear hand can
manual. Do not place the parts on the floor directly. Place
cause burns.
them on a workbench or the like.
Place the engine parts in good order to prevent from miss-
ing. Also, place the parts in the serial order for reassem-
bling.
When reusing the engine parts, unless there are special rea-
sons, install them to their original positions.
Pay attention to assembling marks. Put your marks on the
parts, if necessary, to ensure correct assembling.
Carefully check each part for defects during disassembling
or cleaning. Do not miss symptoms which cannot be
found after finishing the disassembling or cleaning.
Pay attention to the safety, especially for the balancing of
disassembled parts and carrying of heavy parts. (Get the
help, and use jacks, chain blocks and guide bolts as neces-
sary.)
Use protective gloves when you touch overheated or fro-
zen parts. Touching such a part with a bear hand can
cause burns.
XII 99089-40100
GENERAL CONTENTS
Chapter 1 GENERAL
1. External View
2. Outline of Systems
3. Engine serial number
4. Engine model code identification
5. Specifications
Chapter 2 SERVICE DATA

1. Maintenance Service Data
2. Tightening Torque Table
3. Table of sealants and oils
Chapter 3 SERVICE TOOLS

1. General Tools
2. Special Tools
Chapter 4 PERIODIC MAINTENANCE SCHEDULE

1. How to Use the Periodic Maintenance Schedule
2. Periodic Maintenance Chart for Continuous-Use Engine
3. Periodic Maintenance Chart for Emergency-Use Engine
4. Periodic Maintenance Chart for General-Purpose Engine
Chapter 5 PREPARATION FOR DISASSEMBLY

1. Preparation
Chapter 6 DISASSEMBLY OF BASIC ENGINE

1. Cylinder Head and Valve Mechanism - Disassemble and Inspect
2. Rear Mechanism - Disassemble and Inspect
3. Front Mechanism - Disassemble and Inspect
4. Cylinder Liner, Piston, and Connecting Rod - Disassemble and Inspect
5. Crankcase, Crankshaft, and Main Bearing - Disassemble and Inspect
Chapter 7 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder Head and Valve Mechanism - Inspect and Repair
2. Rear Mechanism - Inspect and Repair
3. Front Mechanism - Inspect and Repair
4. Cylinder Liner, Piston and Connecting Rod - Inspect and Repair
5. Crankcase, Main Bearing and Crankshaft - Inspect and Repair
Chapter 8 ASSEMBLY OF BASIC ENGINE
1. Upper Main Bearing, Crankshaft and Crankcase - Assemble
2. Cylinder Liner, Piston, and Connecting Rod - Assemble
3. Front Mechanism - Assemble
4. Rear Mechanism - Assemble
5. Cylinder Head and Valve Mechanism - Assemble
Chapter 9 FUEL SYSTEM

1. Environmental Condition to Disassemble and Assemble the Fuel System
2. Fuel System - Remove and Inspect
3. Fuel System - Disassemble, Inspect, and Assemble
4. Fuel System - Install
Chapter 10 LUBRICATION SYSTEM

1. Lubrication System - Remove and Inspect
2. Lubrication System - Disassemble, Inspect, and Assemble
3. Lubrication System - Install
Chapter 11 COOLING SYSTEM

1. Cooling System - Remove and Inspect
2. Cooling System - Disassemble, Inspect, and Assemble
Chapter 12 INLET AND EXHAUST SYSTEMS

1. Inlet and Exhaust Systems - Remove and Inspect
2. Inlet and Exhaust Systems - Disassemble, Inspect, and Assemble
3. Inlet and Exhaust Systems - Install
Chapter 13 AIR START SYSTEM

1. Air Start System - Remove and Inspect
2. Air Start System - Disassemble, Inspect and Assemble
3. Air Start System - Install
Chapter 14 ADJUSTMENT AND OPERATION

1. Engine - Adjust
2. No-Load Minimum Engine Speed (Idling) and No-Load Maximum Engine Speed - Check and Adjust
3. Test Operation
4. Performance Test
Chapter 1 GENERAL
1. External View ........................................................................................................... 1-3
2. Outline of Systems .................................................................................................. 1-5
2.1 Outline of Fuel System ............................................................................................................. 1-5
2.2 Outline of Lubrication System................................................................................................... 1-5
2.3 Outline of Cooling System ........................................................................................................ 1-6
2.4 Outline of Inlet and Exhaust System......................................................................................... 1-6
2.5 Outline of air start system ......................................................................................................... 1-7
3. Engine serial number .............................................................................................. 1-8
4. Engine model code identification .......................................................................... 1-9
5. Specifications ........................................................................................................ 1-10
99089-40100
1-1
Chapter 1 GENERAL
Chapter 1 GENERAL
1. External View
Turbochaeger
Air cleaner
Secondary oil filter
Oil cooler
Engineoil inlet
(from priming pump
driven with air motor)
Air cooler Coolant outlet
Starting air inlet

Engine body coolant outlet
Priming pump
Engine oil drain

Engine body coolant inlet
Air cooler Coolant inlet
Left Side View
Air cleaner Oil level gage Fuel filter

Oil filler
Governor
Breather
Secondary Fuel return port

oil filter
Fuel inlet
Generator
Starting air Strainer Lube oil inlet(From L/O tank)

Starting solenoid valve Lube oil drain
Lube oil outlet Lube oil outlet Lube oil inlet(From prifier)
㸦Wo priming pump driven (To prifier)
width air motor) Oil level regulator
Right Side View
99089-40100
1-3
Chapter 1 GENERAL
Exhaust gas outlet
Insturument panel
Main terminarl box
Top View
1-4 99089-40100
Chapter 1 GENERAL
2. Outline of Systems
2.1 Outline of Fuel System
Injection pump Injection nozzle Injection pump
Accumulator
Fuel secondary filter

Fuel
To fuel tank priming pump
Nozzle leak To fuel tank
off pipe
Fuel pump
Regulator
relief valve
To fuel tank
Fuel primary filter
Nozzle leak-off pipe From fuel tank
Outline of Fuel System (1CV-Type Injection Pump)

2.2 Outline of Lubrication System
Turbocharger
Valve mechanism
Main gallery
Injection pump
Piston
Camshaft
To oil pan
Distributor
Oil filter
Oil cooler
Governor
Water pump
Idler gear
Crankshaft
Oil strainer
Outline of Lubrication System
99089-40100
1-5
Chapter 1 GENERAL
2.3 Outline of Cooling System
Cooling
tower
Heat exchanger
3 Thermo element
Heat exchanger
3 Air cooler
3
Oil cooler
Outline of Cooling System
2.4 Outline of Inlet and Exhaust System

Turbocharger
Exhaust
TI temperature
Air cleaner
indicator
Cylinder Muffler
Cooling water
Cooling water
Exhaust system
Inlet system Air cleaner
Turbocharger
Outline of Inlet and Exhaust System
1-6 99089-40100
Chapter 1 GENERAL
2.5 Outline of air start system
Distributor valve
Pilot air pipe
Check valve
(pilot air) Main air pipe
Check valve
(main air)
Starting valve
CYL CYL CYL CYL CYL CYL CYL CYL
No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8
Outline of Air Start System
99089-40100
1-7
Chapter 1 GENERAL
3. Engine serial number

The engine serial number is stamped on the nameplate of
the left side of the engine.
Engine serial number

Model
(example)
S16U 10080
Note: The engine serial number is stamped from 10001 in-

crementally according to the shipping order.
The nameplate shows stamped Engine No., Engine Output,
Rated Rotational Speed and others.
Serial No. MFG.Date
Model
DISPLACEMENTࠉࠉࠉࠉ188ࠉ
RATED OUTPUT
ENGINESPEEDࠉࠉࠉࠉࠉࠉmin-1
HEAVY INDUSTRIES,LTD.
TOKYO JAPAN
R1 R2 R3 R4 R5 R6 R7 R8
F R
r e
o
n a
t r
L1 L2 L3 L4 L5 L6 L7 L8
Engine top view
Nameplate location
1-8 99089-40100
Chapter 1 GENERAL
4. Engine model code identification
6 8 㸫 7$ With after-cooler and turbocharger
6 8 㸫 7. With intercooler and turbocharger
3 Generator, General power source

Application
03 Marine generator, Marine general power source
code
0 Marine main engine
Series code
No. of cylinders
99089-40100
1-9
Chapter 1 GENERAL
5. Specifications(for Eastern Rifinery Limited.)

Engine model S16U-PTK
Water cooled, four cycle diesel, turbocharged
Type
With inter cooler
No. of cylinders - Arrangement 16-V
Combustion system Direct injection system
Valve mechanism Overhead valve type
Cylinder bore x stroke ø240 × 260 mm [9.45 × 10.24 in.]
Total displacement 188.2 L [11486.40 cu in.]
Compression ratio 13.5:1
Main
specifications Fuel Diesel fuel (JIS K2204 or equivalent)
or JIS K2205 "A" heavy oil (limited to domestic major brand)
Firing order R1-L1-R6-L6-R2-L2-R4-L4-R8-L8-R3-L3-R7-L7-R5-L5
Forward rotational direction Counterclockwise as viewed from the flywheel to engine
Direction of rotation
Reverse rotational direction Clockwise as viewed from the flywheel to engine
Length 4586 mm [180.55 in.]
Dimensions Width 1710 mm [67.32 in.]
Height 2490 mm [98.03 in.]
Dry weight Approx. 20.5 metric ton 45.190 lb
Cylinder liner Type Wet type (without Anti-polish ring)
Compression ring: 3
Piston ring Quantity
Oil ring (with expander): 1
·1CV-type injection pump spec. Open BTDC 60°
·Valve profile: Old-type cam Intake valve
Close ABDC 48°
spec. ·Connecting method: New-
type cam spec. ·STD injection Open BBDC 79°
Engine
timing 16°BTDC (Adjust to Exhaust valve
14°with cam gear adjustment. ) Close ATDC 53°
Valve clearance Inlet valve 0.6 mm [0.024 in.]

(when cold) Exhaust valve 0.8 mm [0.032 in.]
Engine support method 6-point support
Starting system Compressed air direct type
Model NP-PFR1CV type
Manufacturer Bosch Corporation
Injection pump Plunger diameter ø20 mm [0.79 in.] (1CV type)
Plunger lead Clockwise, 40 mm [1.57 in.] lead on both sides
Cam lift 20 mm [0.79 in.] (1CV type)
Type Trochoid type
Fuel pump Discharge rate
Trochoid type 30.0 L [7.926 US gal.]/min (1500min-1)
(Engine rotational speed)
Fuel Governor Governing system Hydraulic type UG-Actuator (Woodward make)

system Type Hole type
Manufacturer Bosch Corporation
Injection nozzle Orifice number-orifice
1CV type 10-ø0.37 mm [0.0146 in.]-160°
diameter-cone angle
Valve opening pressure 34.8 to 35.3 MPa {354.9 to 360.0 kgf/cm2} [5047.3 to 5119.8 psi]
Fuel injection timing 14°BTDC (1CV-type injection pump, new-type cam spec)
Primary filter Wire mesh element type
Fuel filter
Secondary filter Paper element type
Relief valve Valve opening pressure 0.23 to 0.26 MPa {2.35 to 2.65 kgf/cm2}[33.36 to 37.71 psi]
1-10 99089-40100
Chapter 1 GENERAL
Engine model S16U-PTK

Lubricating method Forced circulation (pressure feed by oil pump)
Standard API service classification CD or CF class
Engine oil
Volume Approx. 600 L [158.52 US gal.]
Type Gear pump type
Speed increasing ration
1.132 (Z=53)
(driven gear teeth number)
Oil pump Discharge rate (Engine rotational speed) 780 L [206.08 US gal.]/min (750min-1)
Lubrication
Type With piston valve
system
Safety valve Valve opening
1.18 MPa {12.03 kgf/cm2} [171.14 psi]
pressure
Oil cooler Type Water-cooled multi-pipe type
Oil filter Type Paper element type
Relief valve Valve opening pressure 0.59 ± 0.05 MPa {6.02±0.50 kgf/cm2} [85.57 ± 7.25 psi]
Type Wax type
Thermostat
Valve opening temperature 55°C [131°F]
Cooling method Forced cooling with a centrifugal pump
Coolant capacity (engine body) Approx. 700 L [184.94 US gal.]
Type Centrifugal turbine type
Cooling Speed increasing ratio
Water pump 2 (Z=30)
system (driven gear teeth number)
Discharge rate (Engine rotational speed) Approx. 1210 L [319.68 US gal.]/min (750min-1)
Type Wax type
Thermostat
Air blow-in 1CV-type injection pump ·STD injection Starting valve open 7°ATDC
timing timing spec. Starting valve close 135°ATDC
Air start
system Regular air pressure 3.0 MPa {30.6 kgf/cm2} [435.1 psi]
Minimum starting air pressure 1.5 MPa {15.3 kgf/cm2}[217.6 psi]
99089-40100
1-11
1. Maintenance Service Data ...................................................................................... 2-3
1.1 General Maintenance Service Data of Engine.......................................................................... 2-3
1.2 Maintenance Service Data of Engine Body .............................................................................. 2-3
1.3 Maintenance Service Data for Fuel System ............................................................................. 2-8
1.4 Maintenance Service Data of Lubrication System .................................................................. 2-10
1.5 Maintenance Service Data of Cooling System ....................................................................... 2-11
1.6 Air start system maintenace service data ............................................................................... 2-12
2. Tightening Torque Table....................................................................................... 2-13
2.1 Tightening Torque for Engine Body ........................................................................................ 2-13
2.2 Tightening Torque Spec for Fuel System ............................................................................... 2-14
2.3 Tightening Torque Specifications for Lubrication System....................................................... 2-14
2.4 Tightening Torque Specifications for Cooling System ............................................................ 2-15
2.5 Tightening Torque Spec for Air Start System ......................................................................... 2-15
2.6 Tightening with the hydraulic jack........................................................................................... 2-15
2.7 Tightening Torque for Standard Bolts..................................................................................... 2-16
2.8 Tightening Torque for Standard Union Bolts .......................................................................... 2-17
2.9 Tightening Torque for Standard Union Nuts ........................................................................... 2-17
2.10 Tightening Torque for Fuel Injection Pipe............................................................................... 2-17
3. Table of sealants and oils ..................................................................................... 2-18
99089-40100
2-1
1. Maintenance Service Data

1.1 General Maintenance Service Data of Engine
Unit: mm [in.]
Nominal
Item Standard value Limit value Remark
value
115%
Maximum speed 105 to 110
- or higher is not Check governor setting.
(based on rated speed) [4.13 to 4.33]
allowed.
Minimum speed - 450 min -1 -
1.9 MPa
2.4 MPa
{19.4 kgf/cm2}
{24.5 kgf/cm2} When oil and water temperatures
Compression pressure (120 to 200 min-1) - [275.6 psi]
[348.1 psi] at 20 to 30°C [68 to 86°F]
or lower is not
allowed.
0.39 to 0.69 MPa 0.29 MPa
Rating - {3.98 to 7.04 kgf/cm2} {2.96 kgf/cm2}
Engine [56.56 to 100.08 psi ] [42.06 psi] Oil temperature 70 to 100°C
hydraulic pres-
0.20 to 0.39 MPa 0.10 MPa [158 to 212°F]
sure
Idling - {2.04 to 3.98 kgf/cm2} [14.50 psi]
[29.01 to 56.56 psi] {1.02 kgf/cm2}
Valve clearance Inlet valve 0.6 [0.024] - -

(when cold) Exhaust valve 0.8 [0.032] - -
Fuel injection 14° ±1°
1 [0.04]CV-type injection pump -
start timing (BTDC) (crank angle)
to the nominal value Refer to the "Valve Timing -
Valve timing of inlet and exhaust valves - -
±4°or less Check" for the nominal value.
1.2 Maintenance Service Data of Engine Body

Unit: mm [in.]
Nominal
value
ø48 48.04 to 48.14 48.24
Rocker bushing inside diameter
[1.89] [1.8913 to 1.8953] [1.8992]
Rocker
ø48 47.984 to 48.000 47.95
Rocker shaft outside diameter
[1.89] [1.8891 to 1.8898] [1.8878]
16.91 to 16.93 16.82
Inlet valve
ø17 [0.6657 to 0.6665] [0.6622]
Valve stem outside diameter
[0.67] 16.88 to 16.90 16.74
Exhaust valve
Valve [0.6646 to 0.6654] [0.6591]
ø17 17.000 to 17.018 17.14 same to the intake and
Valve guide inside diameter
[0.67] [0.6693 to 0.6700] [0.6748] exhaust
Clearance between valve bridge and valve cotter - 0.2 [0.008] or more 1.0 [0.039] or more
99089-40100
2-3
Unit: mm [in.]
Nominal
value
Inlet valve - 30° - Seat width
Valve seat angle
Exhaust valve - 30° (45°) -
1.0 to 1.9
Inlet valve - 2.9 [0.114] Valve
[0.039 to 0.075] Valve Valve margin
seat angle sinkage
Valve sinkage
1.0 to 1.9
[0.039 to 0.075] 2.9 [0.114] The value in ( ) is for
Exhaust valve -
(0.1 to 1.0 (2.0 [0.079]) marine use.
[0.004 to 0.039])
3.8 to 4.2 5.2
Valve seat Inlet valve -
[0.150 to 0.165] [0.205]
ring and
valve Seat width 2.9 to 3.3 The valeve seat angle of
[0.114 to 0.130] 4.3 [0.169] (45°) is the specification
Exhaust valve -
(2.3 to 2.8 (4.4 [0.173]) for marine use and the
[0.091 to 0.110]) heavy fuel oil in China.
5.3 to 5.7 However the specifica-
Inlet valve - 4.7 [0.185] tion varies with the cus-
[0.209 to 0.224]
tomization. Check the
Valve margin 4.3 to 4.7 part for verification.
[0.169 to 0.185] 3.7 [0.146]
Exhaust valve -
(3.8 to 4.2 (3.0 [0.118])
[0.150 to 0.165])
Minus (-) indicates the
Valve seat ring housing inside diameter ø85 -0.140 to -0.180
- interference amount in
and valve seat ring outside diameter, clearance [3.35] [-0.0055 to -0.0071]
diameter.
Free length - 107 [4.21] 102 [4.02]
ǰ
ٌ
Squareness - θ=1°or less In full length Δ=2.8
Lf
Valve spring
100 [3.94]/525
set length / load
- {53.5} [118.0] to -
(mm [in.]/N {kgf} [lbf])
593 {60.5} [133.3]
Clearance between tappet-guide set screw hole and 0.0 to 0.2 1.2
-
set screw [0.000 to 0.008] [0.047]
ø58 58.000 to 58.030
Tappet guide inside diameter -
[2.28] [2.2835 to 2.2846]
ø58 57.921 to 57.940 Products in September,
Tappet outside diameter -
[2.28] [2.2804 to 2.2811] 2000 and after
Clearance between tappet guide inside diameter and 0.06 to 0.109 0.25 Products in September,
-
tappet outside diameter [0.0024 to 0.0043] [0.0098] 2000 and after
Inside ø36 36.025 to 36.066
-
diameter [1.42] [1.4183 to 1.4199]
Tappet roller
Outside ø51 50.9 to 51.1 50.7 Products in November,
Tappet
diameter [2.01] [2.004 to 2.012] [1.996] 1997 and after
Inside ø22 22.150 to 22.190
-
diameter [0.87] [0.8720 to 0.8736]
Tappet roller bushing
Outside ø36 35.870 to 35.890
-
diameter [1.42] [1.4122 to 1.4130]
ø22 22.002 to 22.011
Tapper roller shaft outside diameter -
[0.87] [0.8662 to 0.8666]
Clearance between tappet roller inside diameter and 0.135 to 0.196 0.25
-
tappet-roller bushing outside diameter [0.0053 to 0.0077] [0.0098]
Clearance between tappet-roller bushing inside 0.139 to 0.188 0.25 [
-
diameter and tappet-roller shaft [0.0055 to 0.0074] 0.0098]
Push rod bend - 0.5 [0.020] or less 0.5 [0.020] Runout
2-4 99089-40100
Unit: mm [in.]
Nominal
value
ø240 240.000 to 240.046 240.4
Inside diameter
[9.45] [9.4488 to 9.4506] [9.465]
Cylinder liner
Cylinder head and cylin-
- 0.1 [0.004] or more -
der liner, clearance
Weight difference allowance - 140g [4.938 oz.] - In one engine
General use 0.18 to 0.25 0.3
-
marine [0.0071 to 0.0098] [0.012]
№1 ring
Emergency 0.13 to 0.20 0.3
-
use [0.0051 to 0.0079] [0.012]
Clearance between piston
ring groove and piston 0.09 to 0.16 0.3
No.2 ring -
ring width [0.0035 to 0.0063] [0.012]
Piston
(Inserting new ring)
0.06 to 0.13 0.3
No.3 ring -
[0.0024 to 0.0051] [0.012]
0.04 to 0.11 0.3
Oil ring -
[0.0016 to 0.0043] [0.012]
The limit value shows the
ø100 100.002 to 100.012 0.09
Piston pin hole inside diameter clearance to the piston
[3.94] [3.9371 to 3.9375] [0.0035]
pin.
General use 0.80 to 1.10 1.6
-
marine [0.0315 to 0.0433] [0.063]
№1 ring
Emergency 0.90 to 1.20 1.6
-
use [0.0354 to 0.0472] [0.063]
0.65 to 0.95 1.4
Piston ring Piston ring end gap No.2 ring -
[0.0256 to 0.0374] [0.055]
0.65 to 0.95 1.4
No.3 ring -
[0.0256 to 0.0374] [0.055]
0.75 to 1.05 1.4
Oil ring -
[0.0295 to 0.0413] [0.055]
99.985 to 100.000 0.09
Piston pin outside diameter - clearance to the piston
[3.9364 to 3.9370] [0.0035]
pin bore.
100.05 to 100.11 100.18
Bushing inside diameter -
[3.9390 to 3.9413] [3.9441]
0.05/100
Connecting rod bend and
Connecting rod - [0.0020/3.94] -
twist
or less
Weight difference allow- 100 g [3.527 oz.]
- - In one engine
ance for assembling or less
5.000 -0.88 to -0.068
S.T.D -
[0.1969] [-0.0346 to -0.0027]
-0.25 5.125 -0.88 to -0.068
-
[-0.0098] [0.2018] [-0.0346 to -0.0027]
Center -0.50 5.250 -0.88 to -0.068
-
thickness [-0.0197] [0.2067] [-0.0346 to -0.0027]
-0.75 5.375 -0.88 to -0.068
Connecting rod bearing -
[-0.0295] [0.2116] [-0.0346 to -0.0027]
-1.00 5.500 -0.88 to -0.068
-
[-0.0394] [0.2165] [-0.0346 to -0.0027]
Ellipticity of inside (Max value - min
- -
diameter value) ≤ 0.1 [0.004]
To crank pin 0.136 to 0.500
- -
clearance [0.0054 to 0.0197]
0.33 [0.0130]
Face runout - -
or less
Flywheel
0.13 [0.0051]
Radial runout - -
or less
99089-40100
2-5
Unit: mm [in.]
Nominal
value
Time for silicone oil
level to descend by 30 - 14 min. and 20 sec. 7 min. and 10 sec.
mm [1.18 in.]
Silicone oil
- 5.0 × 10 5 2.5 × 105
Damper kinetic viscosity mm2 /s
Discoloration and
metal particle
Silicone oil color - Colorless and clear
inclusion are
observed.
Inside ø40 39.988 to 40.000
-
diameter [1.57] [1.5743 to 1.5748]
Idler gear bearing
Outside ø90 89.985 to 90.000
-
diameter [3.54] [3.5427 to 3.5433]
ø90 89.955 to 89.990
Inside diameter of idler gear -
[3.54] [3.5415 to 3.5429]
Accessory ø40 39.984 to 40.000
Idler shaft diameter -
drive [1.57] [1.5742 to 1.5748]
ø35 34.984 to 35.000
Oil pump idler shaft diameter -
[1.38] [1.3773 to 1.3780]
Inside ø35 34.988 to 35.000
-
diameter [1.38] [1.3775 to 1.3780]
Oil-pump idler-gear bearing
Outside ø80 79.987 to 80.000
-
diameter [3.15] [3.1491 to 3.1496]
Interference between idler gear inside diameter and -0.045 to 0.005 -0.05 Minus (-) indicates the
-
idler gear bearing outside diameter [-0.0018 to 0.0002] [-0.0020] clearance.
Idler shaft outside diameter and idle gear -0.016 to 0.012 -0.05 Minus (-) indicates the
-
bearing inside diameter, interference [-0.0006 to 0.0005] [-0.0020] clearance.
Oil-pump idler-gear inside diameter and
-0.004 to 0.039 -0.05 Minus (-) indicates the
Oil pump idler gear -
[-0.0002 to 0.0015] [-0.0020] clearance.
bearing outside diameter, interference
Oil pump idler shaft outside diameter and
-0.016 to 0.012 -0.05 Minus (-) indicates the
Oil pump idler gear -
[-0.0006 to 0.0005] [-0.0020] clearance.
bearing inside diameter, interference
0.10 to 0.22 0.5
Accessory Idler gear backlash -
[0.0039 to 0.0087] [0.020]
drive
0.10 to 0.28 0.5
Backlash between idler gear and crank gear -
[0.0039 to 0.0110] [0.020]
High-temper- 0.10 to 0.28 0.5
-
Backlash between idler gear and ature system [0.0039 to 0.0110] [0.020]
water pump gear Low-temper- 0.10 to 0.22 0.5
-
ature system [0.0039 to 0.0087] [0.020]
Backlash between water-pump gear and oil-pump
0.10 to 0.22 0.5
idler gear -
[0.0039 to 0.0087] [0.020]
Idler gear backlash
Oil pump idler gear and 0.10 to 0.22 0.5
-
oil pump gear, backlash [0.0039 to 0.0087] [0.020]
Backlash between camshaft gear and idler gear 0.10 to 0.24 0.50
-
Idler gear backlash [0.0039 to 0.0094] [0.0197]
0.1 to 0.24 0.50
Backlash between idler gear and crank gear -
[0.004 to 0.0094] [0.0197]
0.2 to 0.6 1.0
End play -
Timing [0.008 to 0.024] [0.039]
gear ø85 85.000 to 85.022
Idler bushing inside diameter -
New-type [3.35] [3.3465 to 3.3473]
idler gear ø85 84.942 to 84.964
[3.35] [3.3442 to 3.3450]
Clearance between idler bushing inside 0.036 to 0.080 0.20
-
diameter and idler shaft diameter [0.0014 to 0.0032] [0.0079]
2-6 99089-40100
Unit: mm [in.]
Nominal
value
17 16.980 to 17.020 16.930
Inlet and exhaust cam heights (major axis - minor axis)
[0.67] [0.6685 to 0.6701] [0.6665]
Middle journal deflection
0.05 [0.0020] 0.08
Deflection - (1/2 of runout) when both
or less [0.0032]
ends are supported
Camshaft The limit value shows the

ø128 127.890 to 127.915 0.400 clearance to the cam-
Journal outside diameter
[5.04] [5.0350 to 5.0360] [0.0157] shaft bushing inside
diameter.
Camshaft bushing inside diameter ø128 128.007 to 128.073 0.400
clearance to the cam-
(as installed in crankcase) [5.04] [5.0396 to 5.0422] [0.0157]
shaft journal.
11 mm [0.43 in.] serra- 0.029 [0.0011]
deflection - -
tion connecting rod or less
0.38 to 0.51 0.60
End play -
[0.0150 to 0.0201] [0.0236]
ø180 0 to -0.025 0.136 to 0.500
Crankpin outside diameter clearance to connecting
[7.09] [0.00 to -0.0010] [0.0054 to 0.0197]
rod bearing.
ø200 0 to -0.025 0.147 to 0.500
Crankshaft journal outside diameter clearance to main bear-
[7.87] [0.00 to -0.0010] [0.0058 to 0.0197]
ing.
0.01 [0.0004]
Crank pin parallelism - 0.03 [0.0012]
or less
ø0.01 [0.0004]
Crank journal coaxiality - 0.03 [0.0012]
or less
Crankshaft 0.015 [0.0006]

Roundness - 0.03 [0.0012]
or less
0.01 [0.0004]
Cylindricity - 0.03 [0.0012]
or less
10 9.8 to 10.0
Fillet radius
[0.39] [0.386 to 0.394]
Crank journal and crank
pin General Hs38 to 46
- -
portion (HB255 to 311)
Induction
Hardness hardened por-
Hs>72
tion at crank - -
(Hv>590)
pin and jour-
nal
Middle journal deflection
0.08 [0.0032]
Deflection - 0.3 [0.012] (1/2 of runout) when both
or less
ends are supported
5.000 -0.025
S.T.D -
[0.1969] [-0.0010]
-0.25 [- 5.125 -0.025
-
0.0098] [0.2018] [-0.0010]
Center -0.50 [- 5.250 -0.025
-
thickness 0.0197] [0.2067] [-0.0010]
Main bearing
-0.75 [- 5.375 -0.025
-
0.0295] [0.2116] [-0.0010]
-1.00 [- 5.500 -0.025
-
0.0394] [0.2165] [-0.0010]
ø210 210.147 to 210.176
Housing inside diameter -
[8.27] [8.2735 to 8.2746]
0.147 to 0.500
Clearance between main bearing and crank journal - -
[0.0058 to 0.0197]
99089-40100
2-7
1.3 Maintenance Service Data for Fuel System

Unit: mm [in.]
Item Nominal value Standard value Limit value Remark
0.33 to 0.35
0.35 {3.57} At room tempera-
Accumulator inside pressure: MPa {kgf/cm2} [psi] {3.37 to 3.57} -
[50.76] ture (20°C [68°F])
[47.86 to 50.76]
Injection nozzle Cone angle 160° - -
case-bearing housing inside ø52 51.993 to 52.012
-
diameter [2.05] [2.0470 to 2.0477]
ø52 51.987 to 52.000
Bearing outside diameter -
[2.05] [2.0467 to 2.0472]
Bearing housing inside diameter
-0.025 to 0.007 -0.05
and bearing outside diameter, -
[-0.0010 to 0.0003] [-0.0020]
interference
Case bearing housing inside ø62 61.993 to 62.012
-
diameter [2.44] [2.4407 to 2.4414]
ø62 61.987 to 62.000
[2.44] [2.4404 to 2.4409]
Case bearing housing inside
-0.025 to 0.007
diameter and bearing outside - -0.05 [-0.0020]
[-0.0010 to 0.0003]
diameter, interference
Drive gear ø25 24.990 to 25.000
side Bearing inside diameter -
[0.98 in.] [0.9839 to 0.9843]
Drive gear bearing fitting posi- ø25 25.002 to 25.015
-
tion outside diameter [0.98 in.] [0.9843 to 0.9848]
Bearing inside diameter and
drive gear bearing fitting-posi- 0.020 to 0.025 -0.05
-
tion outside diameter, interfer- [0.0008 to 0.0010] [-0.0020]
ence
Governor drive ø30 29.990 to 30.000
Bearing inside diameter -
[1.18] [1.1807 to 1.1811]
Drive gear bearing fitting posi- ø30 30.002 to 30.015
-
tion outside diameter [1.18] [1.1812 to 1.1817]
drive gear bearing fitting-posi- 0.020 to 0.025 -0.05
-
ence
Case bearing housing inside ø62 61.993 to 62.012
-
diameter [2.44] [2.4407 to 2.4414]
ø62 61.987 to 62.000
[2.44] [2.4404 to 2.4409]
Case bearing housing inside
-0.025 to 0.007
diameter and bearing outside - -0.05 [-0.0020]
[-0.0010 to 0.0003]
diameter, interference
Driven gear
side ø30 29.990 to 30.000
[1.18] [1.1807 to 1.1811]
Driven gear bearing fitting posi- ø30 30.002 to 30.015
-
tion outside diameter [1.18] [1.1812 to 1.1817]
driven gear bearing fitting-posi- 0.020 to 0.025 -0.05
-
ence
2-8 99089-40100
Unit: mm [in.]
0.1 to 0.2
Drive gear and driven gear backlash - -
[0.004 to 0.008]
ø47.5 0.025 to 0.057 0.08
Top clearance between gear and case
[1.870] [0.0010 to 0.0022] [0.0032]
Side clearance between gear width and case 30 0.0 to 0.045 0.07
depth [1.18] [0.000 to 0.0018] [0.0028]
Inside diameter of case and cover needle-roller ø26 25.991 to 26.012
-
fitting-position [1.02] [1.0233 to 1.0241]
ø26 25.991 to 26.000
Needle roller outside diameter -
[1.02] [1.0233 to 1.0236]
Fuel pump Inside diameter of case and cover needle-roller
(gear type) -0.021 to 0.009 -0.05
fitting-positions and needle-roller outside diam- -
[-0.0008 to 0.0004] [-0.0020]
eter, interference
16.992 to 17.000
Needle-roller inside diameter ø17 [0.67] -
[0.6690 to 0.6693]
17.001 to 17.012
Shaft diameter ø17 [0.67] -
[0.6693 to 0.6698]
Interference between needle-roller inside diam- 0.001 to 0.020 -0.05
-
eter and shaft outside diameter [0.0000 to 0.0008] [-0.0020]
0.25 ± 0.02
Relief valve opening pressure:
- [0.0098 ± 0.0007] -
MPa {kgf/cm2} [psi]
{2.5 ± 0.2}
0.25 ± 0.02
Return valve opening pressure: MPa {kgf/cm2} [psi] - [0.0098 ± 0.0007] -
{2.5 ± 0.2}
99089-40100
2-9
1.4 Maintenance Service Data of Lubrication System

Unit: mm [in.]
Backlash between drive gear 0.2 to 0.4 0.5
-
and driven gear [0.008 to 0.016] [0.020]
Top clearance between pump ø110 0.25 to 0.37 0.38
gear teeth and case [4.33] [0.0098 to 0.0146] [0.0150]
Side clearance between gear 160 0.15 to 0.21 0.24
width and case depth [6.30] [0.0059 to 0.0083] [0.0094]
ø44 43.984 to 44.000
Shaft diameter -
[1.73] [1.7317 to 1.7323]
ø44 44.200 to 44.230 [1.7402
Oil pump Bushing inside diameter -
[1.73] to 1.7413]
Clearance between shaft and 0.200 to 0.246 0.3
-
bushing [0.0079 to 0.0097] [0.012]
1.18 MPa 1.08 to 1.27 MPa
Safety valve opening pressure {12.03 kgf/cm2} {11.01 to 12.95 kgf/cm2} -
[171.14 psi] [156.64 to 184.20 psi]
92 mm [3.62 in.] /
Safety valve spring 660 to 728 N
- -
Set length / load {67.3 to 74.2 kgf}
[148.37 to 163.66 lbf]
0.59 ± 0.05 MPa
Relief valve opening
- {6.02 ± 0.50 kgf/cm²} -
pressure
[85.57 ± 7.25 psi]
The value in parentheses
shows the temperature
Oil thermostat valve 55°C [131°F] (70 to
- - where the valve lift
opening temperature 75°C [158 to 167°F])
becomes 11 mm [0.43
in.] or more.
2-10 99089-40100
1.5 Maintenance Service Data of Cooling System

Unit: mm [in.]
Nominal
value
Body bearing housing inside diame- ø90 89.994 to 90.013
-
ter [3.54] [3.5431 to 3.5438]
ø90 89.985 to 90.000
[3.54] [3.5427 to 3.5433]
Clearance between body-bearing Minus (-) indicates the
-0.006 to 0.028 0.05
housing inside diameter and bearing - interference amount in
Water pump [-0.0002 to 0.0011] [0.0020]
outside diameter diameter.
(shaft diameter ø40
[1.57]) ø40 39.988 to 40.000
[1.57] [1.5743 to 1.5748]
Shaft bearing fitting-position diame- ø40 40.002 to 40.018
-
ter [1.57] [1.5749 to 1.5755]
Clearance between bearing inside Minus (-) indicates the
-0.030 to -0.002 0.05
diameter and shaft bearing fitting- - interference amount in
[-0.0012 to -0.0001] [0.0020]
position diameter diameter.
41046-22300 [1615.98] 63 to 67°C
41046-22301 [1615.98] - [145 to 153°F] -
(ID mark 65°C [149°F]) (75°C [167°F])
41046-23400 [1615.98] 69 to 73°C
41046-23401 [1615.98] - [156 to 163°F] - The value in parentheses
(ID mark 71°C [160°F]) (81°C [178°F]) shows the temperature
Thermostat valve
where the valve lift
opening temperature 41046-02700 [1615.98] 58 to 62°C becomes 27 [1.06] or
41046-02701 [1615.98] - [136 to 144°F] more.
(ID mark 60°C [140°F]) (70°C [158°F])
41046-02800 [1615.98] 74.5 to 78.5°C
41046-02801 [1615.98] - [166.1 to 173.3°F] -
(ID mark 76.5°C [169.7°F]) (86.5°C [187.7°F])
99089-40100
2-11
1.6 Air start system maintenace service data

Unit: mm [in.]
17 16.9 to 17.1 16.5
Depth of distributor valve hole Bolt fixing type only
[0.67] [0.665 to 0.673] [0.650]
21.5 21.4 to 21.6 20.5
Distributor valve height Lock-pin type only
[0.846] [0.843 to 0.850] [0.807]
ø20 19.959 to 19.972
Shaft diameter -
[0.79] [0.7858 to 0.7863]
Bolt ø20 20.03 to 20.05
Distributor fixed type [0.79] [0.7886 to 0.7894]
valve Clearance between shaft 0.058 to 0.091 0.2
-
and bushing [0.0023 to 0.0036] [0.008]
ø20 19.959 to 19.980
Shaft diameter -
[0.79] [0.7858 to 0.7866]
Lock-pin ø20 20.03 to 20.05
type [0.79] [0.7886 to 0.7894]
Clearance between shaft 0.050 to 0.091 0.2
-
and bushing [0.0020 to 0.0036] [0.008]
ø21 20.984 to 20.993
Valve outside diameter -
[0.83] [0.8261 to 0.8265]
ø21 21.000 to 21.016
Valve body housing inside diameter -
[0.83] [0.8268 to 0.8274]
Clearance between valve outside diame-
0.007 to 0.032 0.1
ter and valve body housing inside diam- -
[0.0003 to 0.0013] [0.004]
eter
ø30 29.984 to 29.993
Starting valve Piston outside diameter -
[1.18] [1.1805 to 1.1808]
Valve body piston housing inside diame- ø30 30.000 to 30.016
-
ter [1.18] [1.1811 to 1.1817]
Clearance between piston outside diam-
0.007 to 0.032 0.1
eter and valve-body piston housing -
[0.0003 to 0.0013] [0.004]
inside diameter
77 69.7 to 77.3 65
Valve spring free length
[3.03] [2.744 to 3.043] [2.56]
ø18 17.950 to 17.968
[0.71] [0.7067 to 0.7074]
ø18 18.000 to 18.018
Body inside diameter -
[0.71] [0.7087 to 0.7094]
Clearance between valve outside diame- 0.032 to 0.068 0.1
-
Safety valve ter and body inside diameter [0.0013 to 0.0027] [0.004]
110 109.5 to 110.5 105
Valve spring free length
[4.33] [4.311 to 4.350] [4.13]
15.7 15.5 to 16.2
Valve opening pressure:
{160.10} [0.610 to 0.638] -
MPa {kgf/cm2} [psi]
[2277.10] {158 to 165}
Air-tank blow-out pressure MPa {kgf/cm2} [psi] - 3.14 {32.02} [455.42] -
2-12 99089-40100
2. Tightening Torque Table

2.1 Tightening Torque for Engine Body
Thread dia. x Tightening torque
Part to be installed Pitch Remark
(Metric thread) N·m kgf·m lbf·ft
Left side bolt (snug torque) 30 × 3.5 392 40 289.12 Note (a)
Right side bolt (snug torque) 30 × 3.5 196 20 144.56 Note (a)
Side bolt (right and left) 30 × 3.5 883 90 651.27 Note (a)
Apply Locktite 271 to screw-in
Nozzle retainer stud 18 × 2.5 98 10 72.28
threads to cylinder head.
Piston crown fixing bolt 14 × 1.5 59 6 43.52 Note (a)
Damper plug 8 × 1.25 20 2 14.75
Crankshaft oil hole clogging plug 22 × 1.5 118 12 87.03 Note (b)
Screw-in side of cylinder-head stud bolt 33 × 3.5 196 20 144.56 Note (a)
Oil pan mounting bolt 12 × 1.75 57 5.7 42.04
Connecting rod bolt (snug torque) 22 × 1.5 441 45 325.26 Note (d)
Connecting rod bolt (snug torque) 22 × 1.5 245 25 180.70 Note (d)
1CV-type
Camshaft connecting nut 10 × 1.25 68.6 7 50.597
injection pump spec.
Idler shaft
12 × 1.25 98 10 72.28
Thrust plate setting bolt
Timing gear case mounting bolt 12 × 1.75 59 6 43.52
Camshaft gear mounting nut
10 × 1.25 68.6 7 50.597
(1CV-type injection pump, new-type cam spec.)
Camshaft gear mounting bolt.
(1CV-type injection pump, old-type cam spec. 16 × 1.5 145 14.8 106.95
and 1CD-type injection pump spec.)
Flywheel mounting bolt 22 × 1.5 618 63 455.81 See Note (c).
Front gear case mounting bolt 12 × 1.75 57 5.8 42.04
Damper mounting bolts 22 × 1.5 618 63 455.81 See Note (c).
Copper-tube setting nut 52 × 2 147 15 108.42 Apply engine oil to threads.
Rocker-shaft bracket setting screw 10 × 1.5 29.4 3 21.684 Hexagon socket bolt
Rocker-shaft bracket setting nut 10 × 1.5 57.8 5.9 42.631
Rocker bracket setting bolt. 18 × 2.5 235 24 173.33 See Note (c).
Fuel inlet connector 18 × 1.5 88 to 98 9 to 10 64.91 to 72.28
Nozzle retainer nut 18 × 1.5 196 20 144.56 Apply engine oil to threads.
Rocker cover setting screw 12 × 1.75 18 ± 2 1.8 ± 0.2 13.28 ± 1.47
Tighten the bolts evenly to
adjust the height difference of
Indicator valve tap bolt 12 × 1.75 57 5.8 42.04
right and left caps to be within
0.5 mm [0.020 in.].
Note:(a) Apply Moly Grease No.2 (SUMICO) or equivalent to bolt threads.

(b) Apply Locktite 271 or equivalent to threads.
(c) Apply Moly Grease No.2 (SUMICO) or equivalent to bolt threads and bearing face.
(d) For the tightening procedure of connecting rod, refer to "Connecting rod cap - Install" of "ASSEMBLY OF BASIC
ENGINE".
99089-40100
2-13
2.2 Tightening Torque Spec for Fuel System

Fuel primary filter element - 19 2 14.01

Fuel secondary filter (center bolt type) 16 × 1.5 63.7 ± 4.9 6.5 ± 0.5 46.983 ± 3.61
Fuel pump (gear type)
30 × 1.5 186 ± 9 19.0 ± 0.9 137.19 ± 6.63
Relief valve body
Fuel pump (gear type)
20 × 1.5 54 ± 3 5.5 ± 0.3 39.83 ± 2.21
Relief valve cap
Lock nut 16 × 1 39 to 49 4 to 5 28.76 to 36.14
Cap nut 14 × 1 29 to 39 3 to 4 21.39 to 28.76
Injection nozzle Apply Moly Grease No.2

Retaining nut 28 × 1.5 98 to 127 10 to 13 72.28 to 93.67 (SUMICO) or equivalent to bolt
threads.
Fuel inlet connector 18 × 1.5 88 to 98 9 to 10 64.91 to 72.28
Apply Moly Grease No.2
(SUMICO) or equivalent to bolt
Delivery valve setting bolt 14 × 2 78 to 98 8 to 10 57.53 to 72.28 threads.
Apply engine oil to the bolt bear-
ing surface.
Injection pump Apply Locktite 222 or equivalent
Defector bolt 14 × 1.5 20 to 29 2 to 3 14.75 to 21.39 to bolt threads.
Hexagon socket bolt
Apply Locktite 242 or equivalent
Control rack mounting bolt 8 × 1.25 13 to 15 1.3 to 1.5 9.59 to 11.06 to bolt threads.
Hexagon socket bolt
Magnetic-pickup lock nut - 68 ± 13.6 6.9 ± 1.4 50.15 ± 10.03
Fuel injection pipe
18 × 1.5 59 ± 1.0 6.0 ± 0.1 43.52 ± 0.73
Cap nut (nozzle holder side)
Fuel injection pipe
Cap nut (pump side) 22 × 1.5 88 ± 1.0 9.0 ± 0.1 64.91 ± 0.73
(In the case of 1CV-type injection pump)
Injection pump setting bolt
14 × 2 167 ± 17 17.0 ± 1.7 123.17 ± 12.53
(In the case of 1CV-type injection pump)
Injection-pump oil-supply-pipe union bolt
10 × 1.25 15 ± 2.0 1.5 ± 0.2 11.06 ± 1.47 1 to 7 cylinders
(injection pump side)
Injection-pump oil-supply-pipe union bolt
14 × 1.5 34 ± 4.0 3.5 ± 0.4 25.08 ± 2.95
(crankcase side)
2.3 Tightening Torque Specifications for Lubrication System

Apply Moly LG grease to the

Oil pump gear mounting nut 30 × 1.5 245 25 180.70 seat face.
No. 2 (SUMICO)
Oil filter (with center bolt) 16 × 2 78 to 88 8 to 9 57.53 to 64.91
2-14 99089-40100
2.4 Tightening Torque Specifications for Cooling System

V-groove on nut periphery indi-

Water-pump impeller setting nut cates left-hand thread. Apply
20 × 1.5 196 20 144.56
(shaft diameter. ø40 mm [1.57 in.]) ThreeBond 1215 or equivalent to
the washer both sides.
Apply Moly LG grease No.2 to
Water-pump-gear setting nut
36 × 1.5 392 40 289.12 thread.
(shaft diameter ø40 mm [1.57 in.])
(SUMICO) or equivalent
2.5 Tightening Torque Spec for Air Start System

Distributor valve
10 × 1.5 76.6 7.8 56.497
Setting bolt (bolt fixing type)
Starting valve spring tap bolt 8 × 1.25 29.4 ± 1.96 3.0 ± 0.2 21.684 ± 1.44
Tighten the bolts evenly to adjust
the height difference of right and
Starting valve cap setting bolt 12 × 1.75 57 5.8 42.04
left caps to be within 0.5 mm
[0.020 in.].
Safety-valve spring tap bolt 27 × 3 294 30 216.84
Tighten the bolts evenly to adjust
the height difference of right and
Safety-valve body setting bolt 12 × 1.75 57 5.8 42.04
left caps to be within 0.5 mm
[0.020 in.].
2.6 Tightening with the hydraulic jack
Thread dia. x Hydraulic jack pressure

Part to be installed Remark
Pitch MPa kgf·cm2 psi
Cylinder Head Tightening Nut 33 × 1.5 63.7 650 9246 Note (a)
Main bearing cap tightening nut 42 × 1.5 63.7 650 9246 Note (b)
Note:(a) Use the head hydraulic jack 41091-04000.

(b) Use the cap hydraulic jack 41091-04000.
99089-40100
2-15
2.7 Tightening Torque for Standard Bolts

Thread size Width across Strength classification
Threads Dia. × Pitch flats
(M-thread) (mm) [in.] 7T 10.9
7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
8 × 1.25 12 [0.47] 17 1.7 12.54 30 3.1 22.13
10 × 1.25 14 [0.55] 33 3.4 24.34 60 6.1 44.25
Metric automobile 12 × 1.25 17 [0.67] 60 6.1 44.25 108 11.0 79.66
screw thread 14 × 1.5 22 [0.87] 97 9.9 71.54 176 17.9 129.81
16 × 1.5 24 [0.94] 145 14.8 106.95 262 26.7 193.24
18 × 1.5 27 [1.06] 210 21.4 154.89 378 38.5 278.80
20 × 1.5 30 [1.18] 291 29.7 214.63 524 53.4 386.48
22 × 1.5 32 [1.26] 385 39.3 283.96 694 70.8 511.87
24 × 1.5 36 [1.42] 487 49.7 359.19 878 89.5 647.58
27 × 1.5 41 [1.61] 738 75.3 544.32 1328 135.4 979.48
N·m kgf·m lbf·ft N·m kgf·m lbf·ft

10 × 1.5 14 [0.55] 32 3.3 23.60 58 5.9 42.78
12 × 1.75 17 [0.67] 57 5.8 42.04 102 10.4 75.23
Metric course screw
14 × 2 22 [0.87] 93 9.5 68.59 167 17.0 123.17
thread
16 × 2 24 [0.94] 139 14.2 102.52 251 25.6 185.13
18 × 2.5 27 [1.06] 194 19.8 143.09 350 35.7 258.15
20 × 2.5 30 [1.18] 272 27.7 200.62 489 49.9 360.67
22 × 2.5 32 [1.26] 363 37.0 267.74 653 66.6 481.63
24 × 3 36 [1.42] 468 47.7 345.18 843 86.0 621.76
27 × 3 41 [1.61] 686 70.0 505.97 1236 126.0 911.63
Note:(a) The tightening torque listed in this table is for standard bolts and nuts.
(b) The numerical values in the table are the values when spring washers are used.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions. (Dry)
2-16 99089-40100
2.8 Tightening Torque for Standard Union Bolts

Strength classification
Thread size
Width across flats
Dia. × Pitch 4T
(mm) [in.]
(M-thread)
N·m kgf·m lbf·ft
8 × 1.25 12 [0.47] 8±1 0.8 ± 0.10 5.90 ± 0.73
10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.20 11.06 ± 1.47
12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.30 18.44 ± 2.21
14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.40 25.08 ± 2.95
16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.50 32.45 ± 3.68
18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.50 54.58 ± 3.68
20 × 1.5 27 [1.06] 98 ± 10 10.0 ± 1.01 72.28 ± 7.37
24 × 1.5 32 [1.26] 147 ± 15 15.0 ± 1.52 108.42 ± 11.06
27 × 1.5 41 [1.61] 226 ± 20 23.0 ± 2.03 166.69 ± 14.75
(Dry)
2.9 Tightening Torque for Standard Union Nuts

Cap nut thread size
Width across flats
Nominal Dia. × Pitch N·m kgf·m lbf·ft
(mm) [in.]
(M-thread)
63 14 × 1.5 19 [0.75] 39 4.0 28.76
80 16 × 1.5 22 [0.87] 49 5.0 36.14
100 20 × 1.5 27 [1.06] 78 8.0 57.53
120 22 × 1.5 30 [1.18] 98 10.0 72.28
150 27 × 1.5 32 [1.26] 157 16.0 115.80
180 30 × 1.5 36 [1.42] 196 20.0 144.56
200 30 × 1.5 36 [1.42] 196 20.0 144.56
220 33 × 1.5 41 [1.61] 245 25.0 180.70
254 36 × 1.5 41 [1.61] 294 30.0 216.84
(Maximum tolerance value: ±10%, dry condition)
2.10 Tightening Torque for Fuel Injection Pipe

Cap nut thread size
N·m kgf·m lbf·ft
Dia. x Pitch
M 12 X 1.5 35 ± 5 3.6 ± 0.5 25.81 ± 3.68
M 14 X 1.5 40 ± 5 4.1 ± 0.5 29.50 ± 3.68
M 18 X 1.5 59 ± 1 6 ± 1.0 43.52 ± 0.74
M 22 X 1.5 88 ± 1 9 ± 1.0 64.91 ± 0.74
(Dry condition)
99089-40100
2-17
3. Table of sealants and oils

Classification Applied place Sealants and oils Application procedure
Sliding places in engine Engine oil Apply to sliding part.
Apply to sealing-cap outer circumfer-
Cylinder-head sealing cap ThreeBond 1215 or equivalent.
ence.
Apply to screw-in threads to cylinder
Cylinder-head exhaust-flange stud bolt Locktite 271 or equivalent
head.
Injection nozzle sleeve ThreeBond 1215 or equivalent. Apply to sleeve bottom face.
Liner flange bottom face, joint posi-
ThreeBond 1215 or equivalent.
Cylinder liner tion to crankcase
Grease O-ring
Crankcase sealing cap Apply to sealing-cap outer circumfer-
ThreeBond 1215 or equivalent.
(Water chamber, main gallery rear end) ence.
Engine body
Gasket between oil pan and crankcase ThreeBond 1215 or equivalent. Apply only to the gasket joint and end
Crankshaft rear new-type oil seal Engine oil Apply to lip.
Crankshaft front oil seal and crankshaft rear Engine oil Apply to lip.
Old type oil seal ThreeBond 1215 or equivalent. Apply to periphery.
Apply to screw-in threads to cylinder
Cylinder-head nozzle-retaining stud bolt Locktite 271 or equivalent
head.
Crankshaft oil hole clogging plug Locktite 271 or equivalent Apply engine oil to threads.
Starting valve Grease Apply to valve and piston sliding part.
Apply only to gasket end
Gasket between timing gear case and crankcase ThreeBond 1215 or equivalent.
(V-type gasket joint)
Oil system Oil pump cover and case ThreeBond 1215 or equivalent. Apply to packing both sides.
Oil seal Engine oil Lop face (inside seal only)
ThreeBond 1102 or equivalent. Apply to cartridge periphery.
Cooling Water pump Unit seal
LLC Apply to cup gasket periphery.
system
Washer ThreeBond 1215 or equivalent. Apply to both sides.
Thermostat seal ThreeBond 1215 or equivalent. Apply to periphery.
Injection nozzle Moly Grease No.2 or equivalent Tip setting bearing face
Fuel pump (trochoid type) Grease Oil seal lip
Fuel system
Apply to oil supply and drain connec-
Wooward governor lubrication oil connector Locktite 592 or equivalent tor threads
(Do not use PTFE thread seal tape))
Turbcharger lubrication pipe Protector tape (83161-01600) Wind around pipe.
Others Taper plug, cock taper thread free from microen-
PTFE thread seal or equivalent Wind two turns on thread.
capsulated thread lock treatment
2-18 99089-40100
1. General Tools........................................................................................................... 3-3
2. Special Tools............................................................................................................ 3-5
99089-40100
3-1
1. General Tools

No. Tool name Part number Remark

- Tool set 41091-01000 Includes parts No. 1 through 26
1 Spanner F9600-07008 Width across flats (7 × 8 mm [0.28 × 0.32 in.])
8 Socket F9614-17000 Width across flats (17 mm [0.67 in.])
13 Adapter 33491-03600 19.15 × 12.7 mm [0.7539 × 0.500 in.] square drive
14 Universal joint F9617-10000 12.7 mm [0.500 in.] square drive, L = 75 mm [2.95 in.]
15 Extension bar F9615-25000 12.7 mm [0.500 in.] square drive, L = 250 mm [9.84 in.]
16 Slide handle F9618-30000 12.7 mm [0.500 in.] square drive, L = 300 mm [11.81 in.]
17 Pliers F9630-15000 L = 150 mm [5.91 in.]
18 Feeler gauge 30091-06501 9 piece set MIN 0.04 to MAX 0.30 mm [0.0118 in.]
19 Screw driver F9621-15000 (-)
20 Screw driver F9626-20000 (+)
21 Offset wrench F9612-12014 Width across flats (12 × 14 mm [0.47 × 0.55 in.])
22 Offset wrench F9612-22024 Width across flats (22 × 24 mm [0.87 × 0.94 in.])
23 Socket 41091-01200 Width across flats (18 mm [0.71 in.])
99089-40100
3-3
No. Tool name Part number Remark

Nozzle remover
24 41091-01300
(Sliding hammer)
25 Adapter 41091-02501
26 Tool box 03720-00000
3-4 99089-40100
2. Special Tools
Maintenance
Tool name Part number Shape Intended use
item
General Filter wrench 32591-22100 Various cartridges (oil filter, fuel fil-
ter) install/remove
Socket 41091-00700 Width across flats 46

Square drive 25.4 mm [1.000 in.]

Torque wrench 45721-99910 40 to 280 N·m{4.1 to 28.6 kgf·m}

[29.50 to 206.52 lbf·ft]
Torque wrench 45721-99930 98 to 980 N·m {10.0 to 99.9 kgf·m}

[72.28 to 722.81 lbf·ft]
Disassembling Indicator 41091-10100 Cylinder pressure, measure

judgment and
measuring/test-
ing
Indicator valve 41002-12000 Cylinder pressure, measure
Indicator adaptor 41091-30502 Cylinder pressure, measure
99089-40100
3-5
Maintenance
item
Disassembling Gasket F4202-20000 Cylinder pressure, measure
judgment and
measuring/test-
ing
Contact check gauge 41091-06900 Cylinder liner, cylinder head sealing

face contact, check
Crankcase upper sealing face contact,
check
Engine Head hydraulic jack 41091-04000 Cylinder head setting nut, install/
remove
Hydraulic hoses 05312-02100 Use with head hydraulic jack
Hydraulic hand pump 41091-02001 Cylinder head, main bearing cap,

install/remove
Cylinder head polisher 41091-06800 Cylinder head gas sealing face, reface
Shaft 41091-02600 Cylinder head setting nut, main bear-

ing setting nut, turn
Valve spring presser 41091-11400 Valve spring, install/remove
Copper tube installer 41091-02200 Copper-tube, install
3-6 99089-40100
Maintenance
item
Engine Valve guide installer 41091-01900 Valve guide, pull-out/tap-in
Valve seat ring installer 41091-02100 Valve seat ring, install
Copper tube nut wrench 41091-03700 Copper-tube setting nut, tighten
Stem seal installer 41091-01600 Stem seal, install
Copper tube pull-out 41091-08700 Copper tube, pull-out

adapter
Valve lapper 30091-08800 Intake and exhaust valve seat, lap
Oil seal installer 41091-04900 Front oil seal, install

Wate pump gear mounting nut
Camshaft guide 41091-02900 Camshaft, install/remove
99089-40100
3-7
Maintenance
item
Engine Ring wrench 41091-08600 Width across flats 14
Camshaft connecting nut, tighten
Damper plug wrench 41091-09500 Damper plug, install/remove
Deflection gauge 41291-10100 Crankshaft deflection, measure
Cap hydraulic jack 41091-03500 Main bearing cap nut, install/remove
Main bearing removing pin 41091-11800 Main bearing, remove
Crankcase polisher 41091-06700 Crankcase upper sealing face, reface
Cylinder liner remover 41091-20400 Cylinder liner, remove
Cylinder liner polisher 41091-06600 Cylinder liner gas sealing face, reface
Piston remover 41091-10600 Piston, install/remove
3-8 99089-40100
Maintenance
item
Engine Piston ring pliers 41091-12400 Piston ring, install/remove
Piston installer 41091-04400 Piston, install

Connecting rod cap mounting bolt
Extension bar 41091-00900 Square drive 25.4 mm [1.000 in.]

Connecting rod cap mounting bolt
Fuel system Copper tube installer 41091-02200 Injection nozzle sleeve, install
Nozzle tester 83091-03301 Nozzle injection test
Spanner head 41091-08200 Width across flats 24

(use with 41091-08100)
Fuel-injection-pipe pump side nut,
tighten
Spanner head 41091-08400 Width across flats 32

(use with 41091-08100)
Fuel-injection-pipe pump side nut,
tighten
Torque wrench 41091-08100 Fuel injection pipe setting nut, cam-

shaft connecting nut, tighten
99089-40100
3-9
Maintenance
item
Fuel system Adapter 41091-07500 Fuel injection pump shaft, pull-out
Fuel injection pump 41091-03800 1CV-type (for high-pressure) fuel

injection pump, disassemble
Air start system Socket 41091-07700 Width across flats 36

Starting valve spring pressing nut,
mounting bracket installing bolt,
tighten
3-10 99089-40100
Chapter 4 PERIODIC MAINTENANCE SCHEDULE
1. How to Use the Periodic Maintenance Schedule.................................................. 4-3
1.1 Category of Periodic Maintenance Chart.................................................................................. 4-3
1.2 General Definition of Continuous-Use, Emergency-Use and General-Purpose Engines ......... 4-3
2. Periodic Maintenance Chart for Continuous-Use Engine.................................... 4-4
3. Periodic Maintenance Chart for Emergency-Use Engine .................................... 4-8
4. Periodic Maintenance Chart for General-Purpose Engine................................. 4-12
99089-40100
4-1
Chapter 4 Periodic Maintenance Schedule
1. How to Use the Periodic Maintenance Schedule

The periodic service not only extends the service life of the engine but also serves to ensure a safety operation. Be sure to con-
duct services according to the Periodic Maintenance Chart.
Obey the Chart for the standard service intervals.
Whenever you notice the abnormalities below, conduct the service work of the defective part, regardless of the recommended
maintenance intervals in the maintenance chart; abnormal noise, excessive amount of black or white smoke, abnormally high
exhaust temperature, abnormal vibration, fuel, oil and exhaust gas leak, and others.
Note: An appropriate service interval varies with such many conditions as the usage, operation, fuel, lubrication and cooling.
Adjust the service interval referring to the Chart records.
When the service interval contains items with shorter service intervals, conduct servicing including the item to be serviced in an
shorter interval.
1.1 Category of Periodic Maintenance Chart

The service interval varies with thr engine specifications. According to the three categolies below conduct the service.
1.1.1 Periodic Maintenance Chart for Continuous-Use Engine
Conduct the service of a continuous-use engine according to the Periodic Maintenance Chart for Continuous-Use Engine.
1.1.2 Periodic Maintenance Chart for Emergency-Use Engine
Conduct the service of an emergency-use engine according to the Periodic Maintenance Chart for Emergency-Use Engine.
Due to the nature of the emergency-use engine, it is subject to demanding operational conditions such as quick start-up and
immediate power supply. In addition, the engine must perform the function in an emergency without fail. Therefore, be sure to
perform the daily inspection, and also conduct the following operation for maintenance purpose.
(1) Once every week: Operate the engine under no load (for 3 to 5 minutes).
(When operating the engine for the adjustment of peripheral devices, limit the operation within 10 minutes.)
(2) Once every month: Operate the engine (at a load of 50% or higher for 15 to 30 minutes).
(3) if the engine cannot be operated every month, operate the engine for 2 hours or more (at a load of 50% or higher).
(4) Check the startability, engine oil pressure, exhaust color, vibration and others.
1.1.3 Periodic Maintenance Chart for General-Purpose Engine
Conduct the service of a general-purpose engine according to the Periodic Maintenance Chart for General-Purpose Engine.
1.2 General Definition of Continuous-Use, Emergency-Use and General-Purpose Engines

1.2.1 General definition of continuous-use engine
An engine used for a constant load which is continuously applied as the base load in a parallel operation with commercial grid.
Or an engine used for a rated load to supply electricity instead of the commercial grid. The load generally fluctuates in a day.
1.2.2 General definition of emergency-use engine
An engine used for an emergency use in the blackout of normal power source of main or commercial grid.
1.2.3 General definition of general-purpose engine
An engine used for the pump drive, marine propulsion, industrial vehicle, and others except for the generator use. The load and
speed are basically constant or fluctuate in a cycle.
99089-40100
4-3
2. Periodic Maintenance Chart for Continuous-Use Engine

Service Intervals Service item Service contents
Every day Inspect leakage, and looseness of bolts and nuts. Retighten
External
bolts and nuts.
Fuel tank Inspect fuel level, and drain water.
Fuel primary filter
Clean inside with the cleaning handle.
(Wire mesh element type)
Check the oil level with the oil level gauge. Refill if neces-
Engine oil
sary. Check the level regulator operation.
Cooling water Check the water level with the fluid level gauge, and refill.
Air cleaner Check clogging with the air cleaner indicator.
Air tank Check air pressure, and drain water.
Check operating hours, performance records, noise, vibra-
Operating condition
tion and instrument operating conditions.
Air cooler Check air cooler chamber for water leak, and drain water.
Every 500 service hours Fuel filter
Drain water.
(Wire mesh element type, center bolt type)
Check looseness of ball joints, bolts, nuts and smooth move-
Fuel control link.
ment.
Check fuel and water mixing.
Engine oil Property analysis (with engine oil analysis service)
Replace.
Oil filter and bypass oil filter. Replace.
Exhaust pipe and exhaust muffler Check, and drain water.
Air compressor Drain water.
Zink rod Check and replace.
Initial 1500 service Valve clearance Inspect and adjust (including rocker room check).
hours
Camshaft and tappet Inspection
Retighten mounting nuts.
Air cooler cover (Also after initial 1500 service hours after gasket replace-
ment.)
Every 1500 service Fuel filter
Replace.
hours (Wire mesh element type, center bolt type)
Cooling water Check LLC concentration.
Pre-cleaner Clean and inspect.
Air cleaner element Clean and inspect.
Air strainer Drain water and clean.
Every 3000 service Valve clearance Inspect and adjust (including rocker room check).
hours
Injection nozzle Replace nozzle tips and adjust the pressure.
Fuel primary filter
Disassemble and clean inside.
Breather Check and clean mist separator. Replace expendables.
Governor oil filter Replace.
Pre-cleaner Replace.
Air cleaner element Replace.
Check clearance to flywheel, foreign subjects on the tip, set-
Magnetic pickup ting nut looseness, wire disconnection, loose connector and
others.
3000 service hours or 2
years, whichever comes Fuel system accumulator Refill nitrogen gas.
first
4-4 99089-40100

Every 6000 service Camshaft and tappet Inspection
hours
Crankcase Remove side cover and check inside.
Water pump Replace oil seals, unit seals and other expendables.
Check silicone oil leak.
Damper
Check temperature with thermo label.
Turbocharger Check shaft and wheel rotation, and thrust for looseness.
Fuel system, oil system, instrument pipes and air start sys-
Check interference and wear. Repair rubber tape.
tem pipe clamp.
years, whichever comes Cooling water Replace.
first
Every 12000 service Top overhaul (Remove the cylinder head to service.)
hours
Disassemble, service, clean and replace expendables.
Valve seat Inspect, grind and lap.
Cylinder head gasket Replace.
Copper tube Replace, replace O-ring
Inlet and exhaust valves Inspect, grind and lap.
valve guides,
valve rotator,
Cylinder head and valve
valve cotter,
mechanism
push rod,
rocker arm bushing,
valve springs, Inspection
tappet rollers,
tappet roller bushings,
tappet shafts,
tappet guides,
tappet guide set screws
Stem seal Replace.
Safety valve Inspect and replace expendables.
Cylinder liner Inspect and clean.
Piston Inspect by removing from engine inside and clean.
Piston ring Replace.
Check bolts. Apply magnetic particle inspection on serra-
Connecting rod
tion. Replace big end bearings. Check small end bushing.
Crankshaft Check deflection and adjust.
Damper Analyze silicone oil properties and change thermo label.
Front gears and timing gears Inspect gear teeth.
99089-40100
4-5

Every 12000 service Fuel control link. Replace ball joints and ball bearings.
hours
Injection pump Disassemble to service, and replace deflectors and O-rings.
Fuel pump
Replace oil seals and O-rings.
(trochoid type)
Fuel system Fuel injection pipe Replace.

Fuel injection timing Inspect and adjust.
Relief valve Inspection
Accumulator Replace.
Fuel pipe Replace O-rings and sealing washers.
Oil pump Replace bushing.
Oil cooler Check element and clean.
Lubrication system
Relief valve Disassemble to service.
Oil pipe Replace O-rings and gaskets.
Water pump Replace bearings
Cooling system
Water pipe Replace O-ring.
Remove carbon deposit, and replace seal rings, bearings and
Turbocharger
expendables.
Air cooler Clean element.
Inlet and Air cooler cover Replace gasket.
exhaust systems
Inlet pipe Replace O-ring.
Exhaust pipe Replace gaskets and nuts.
Exhaust duct Replace V-clamp.
Starting valve Inspect, lap, and replace O-rings and gaskets.
Air pipe Replace gasket.
Air start system
Air tank Check safety valve operation.
Distributor Replace valve, shaft, bushings, pins and gaskets.
Water temperature, oil pressure,
Protective device engine speed and emergency Operational check
stopping devices
Flexible hoses Replace.
4-6 99089-40100

Every 24000 service Major overhaul (complete disassemble and inspection) Replace all O-rings, gaskets and seals.
hours
Replace inlet and exhaust valves, valve seat rings, valve guides, valve guides, valve rotators and
Cylinder head and valve valve cotters.
mechanism Inspect and replace push rods, rocker arm bushings, valve springs, tappet rollers, tappet roller
bushings, tappet shafts, tappet guides and tappet guide set screws.
Cylinder liner Replace.
Check caps and bolts. Replace mainbearings and thrust
Main bearing
plates.
Cam bushing Inspect. Replace at the second 24000 hour service.
Piston Disassemble and check piston crown. Replace O-ring.
Connecting rod Replace connecting rod bolts and small end bushing.
Crankshaft Check the journal and pin. Replace the slinger.
Damper Replace at the second 24000 hour service.
Disassemble and service, performed at the spring coupling
Spring coupling
manufacturer.
Shaft general Inspection
Timing gears and front Rear idler gear Inspect and replace gear assembly (including bushings)
gears
Replace front idler gear bearing, camshaft roller bearing, front seal, rear seal, front gear case
gasket and rear gear case gasket.
Injection nozzle Replace nozzle hoder assembly..
Injection pump Replace plunger assembly and delivery valve.
Fuel system Fuel pump
Replace pump assembly.
(trochoid type)
Relief valve Relief valve
Oil pump Replace safety valve and snap ring.
Oil thermostat Replace.
Engine oil system
Oil pan Clean and replace gasket.
Relief valve Check and replace.
Water pump Replace shaft and impeller.
Cooling system
Cooling water thermostat. Replace.
Air cooler Replace at the second 24000 hour service.
Inlet and
Exhaust pipe Inspect and replace bellows.
exhaust systems
Exhaust duct Replace seal ring.
Disassemble and service, performed at the governor manu-
Actuator
facturer.
Governor
Governor case Replace bearing, O-ring and gasket.
Control shaft Replace oil seal.
99089-40100
4-7
3. Periodic Maintenance Chart for Emergency-Use Engine

Every week Operate the engine under no load for 3 to 5 minutes.
Check startability, exhaust smoke color, abnormal vibration,
noise and smell.
Operation for Maintenance Purpose
Check the indication of various instrument (oil pressure,
water temperature, oil temperature, exhaust temperature,
rotational speed and others.)
Inspect leakage, and looseness of bolts and nuts. Retighten
External
bolts and nuts.
Fuel tank Check oil level.
Engine oil
Starter air tank Check air pressure.
Every month Operate the engine at a load of 50% or higher for 15 to 30
minutes.
Operation for Maintenance Purpose noise and smell.
Fuel primary filter
Fuel control link.
ment.
Engine oil Check fuel and water mixing.
Pre-cleaner Check clogging.
Air tank Drain water.
Every six months Fuel filter
Drain water.
(Wire mesh element type, center bolt type)
At 6 months or 500 ser-
vice hours whichever Zink rod Check and replace.
comes first
At one year or 500 ser-
vice hours whichever Engine oil Property analysis (with engine oil analysis service)
comes first
4-8 99089-40100

Every year Loaded operation at 50% or higher for 2 hours or more.
Operation for Maintenance Purpose
noise and smell.
(when the loaded operation can not be conducted every
month)
Valve clearance Inspect and adjust (including rocker room check).
Damper Check silicone oil leak, and temperature with thermo label.
others.
Fuel tank Drain water.
Injection nozzle Check nozzle tip, and adjust nozzle opening pressure.
Air cleaner element Clean and inspect.
Protective device engine speed and emergency Operational Check
stopping devices
At 2 years or 500 ser- Engine oil Replace.
vice hours whichever
comes first Oil filter and bypass oil filter. Replace.
At 2 years or 1500 ser- Fuel secondary filter

Replace.
vice hours whichever (Center bolt type and cartridge type)
comes first
Fuel primary filter
Every 2 years Turbocharger Check shaft and wheel rotation, and thrust for looseness.
Fuel system accumulator Refill nitrogen gas.
Cooling water Replace.
Cooling water thermostat. Inspection
Distributor Check valve, shaft, bushing and pin. Replace gasket.
Air strainer Drain water and clean.
99089-40100
4-9

Every 4 years Top Overhaul
Disassemble cylinder head, piston and connecting rod of a cylinder and check. If any defect is observed disassemble all the
cylinders.
valve guides,
valve rotator,
Cylinder head and valve valve cotter,
mechanism push rod,
rocker arm bushing,
tappet rollers,
tappet shafts,
tappet guides,
Stem seal Replace.
Piston ring Inspection
Connecting rod
tion. Check big end bearings. Check small end bushing.
Crankshaft Check deflection, and adjust. Check journals and pins.
tem pipe clamp.
Flexible hoses Replace.
Fuel system Injection pump Disassemble to service, and adjust. Replace O-rings.
Fuel tank Clean inside.
Oil pump Visual inspection of discoloring.
Lubrication system
Breather Clean mist separator, and replace expendables.
Turbocharger Clean carbon, and replace seal rings and expendables.
Inlet and Air cooler Clean element.

exhaust systems Pre-cleaner Replace.
4-10 99089-40100

Every 8 years Major overhaul (complete disassemble and inspection) Replace all O-rings, gaskets and seals.
Inlet and exhaust valves, and
Inspect, grind and lap.
valve seat rings
valve guides,
valve rotator,
valve cotter,
push rod,
rocker arm bushing,
mechanism
tappet rollers,
tappet shafts,
tappet guides,
Stem seal Replace.
Copper tube,
Replace.
Copper tube O-ring
Cylinder liner Inspect, clean and replace O-rings.
Inspect main bearing cap and bolts.
Main bearing
Check main bearings and thrust plates.
Cam bushing Inspection
Connecting rod
tion. Check big end bearings. Check small end bushing.
Check gear teeth, bearings and shafts.
Front gears and timing gears Replace front seal, rear seal, front gear case gasket and rear
gear case gasket.
Fuel pipe Replace O-rings and seal washers.
Fuel control link. Replace ball joints and ball bearings.
Fuel system Fuel system accumulator. Replace.
Fuel pump
(trochoid type)
injection pipe Inspection
Oil pump Disassemble to service.
Oil thermostat Inspection
Lubrication system
Oil pipe Replace O-ring and gasket.
Water pump Replace oil seals, unit seals, expendables and bearings.
Cooling system
Air cooler cover Replace gasket.
Inlet and Inlet pipe Replace O-ring.

exhaust systems Exhaust pipe Replace gaskets and nuts.
Exhaust duct Replace seal rings, gaskets and V-clamps.
Air start system
Actuator
facturer.
Governor
99089-40100
4-11
4. Periodic Maintenance Chart for General-Purpose Engine

Every day Inspect leakage, and looseness of bolts and nuts. Retighten
External
bolts and nuts.
Fuel tank Inspect fuel level, and drain water.
Fuel primary filter
Engine oil
Air tank Check air pressure, and drain water.
Check operating hours, performance records, noise, vibra-
Operating condition
tion and instrument operating conditions.
At 500 service hours or Fuel filter Drain water.
every month whichever
comes first Fuel control link.
ment.
Engine oil Check fuel and water mixing.
At 6 months or 500 ser-
vice hours whichever Zink rod Check and replace.
comes first
500 service hours or one Replace.
year, whichever comes Engine oil
Property analysis (with engine oil analysis service)
first
Oil filter and bypass oil filter. Replace.
At the initial 1500 ser- Valve clearance Inspect and adjust (including rocker room check).
vice hours or the first
one year whichever
comes first Retighten mounting nuts.
Air cooler cover (At the initial 1500 service hours or the first one year which-
ever comes first after gasket replacement)
1500 service hours or Fuel filter Replace.
one year, whichever
comes first
Cleaner element Clean and inspect.
Starting air strainer Drain water and clean.
Every 3000 service Valve clearance Inspect and adjust (including rocker room check).
hours
Every 3000 service Fuel primary filter
hours or 2 years, which- (Wire mesh element type)
ever comes first
Breather Check and clean mist separator. Replace expendables.
Pre-cleaner Replace.
others.
Fuel system accumulator Refill nitrogen gas.
4-12 99089-40100

6000 service hours or 4 Camshaft and tappet Inspection
years, whichever comes
first
Water pump Replace oil seals, unit seals and other expendables.
Damper Check silicone oil leak, and temperature with thermo label.
Turbocharger Check shaft and wheel rotation, and thrust for looseness.
tem pipe clamps.
Protective device engine speed and emergency Inspect operation.
stopping devices
12000 service hours or 4 Flexible hoses Replace.
first Fuel system accumulator. Replace.

years, whichever comes Cooling water Replace.
first
12000 service hours or 8 Top overhaul (Remove the cylinder head to service.)
first
Copper tube Replace, replace O-ring
valve guides,
valve rotator,
valve cotter,
mechanism
push rod,
rocker arm bushing,
tappet rollers,
tappet shafts,
tappet guides,
Stem seal Replace.
Connecting rod
tion. Replace big end bearings. Check small end bushing.
Crankshaft Check deflection and adjust.
Front gears and timing gears Inspect gear teeth.
Fuel control link. Replace ball joints and ball bearings.
Injection pump Disassemble to service, and replace deflectors and O-rings.
Fuel pump
(trochoid type)
Fuel system
injection pipe Replace.
Fuel pipe Replace O-rings and sealing washers.
99089-40100
4-13

12000 service hours or 8 Oil pump Replace bushings.
first Lubrication system
Oil pipe Replace O-rings and gaskets.
Water pump Replace bearings
Cooling system
Remove carbon deposit, and replace seal rings, bearings and
Turbocharger
expendables.
Air cooler Clean element.
Inlet and Air cooler cover Replace gasket.
exhaust systems
Inlet pipe Replace O-ring.
Exhaust pipe Replace gaskets and nuts.
Exhaust duct Replace V-clamp.
Air start system
Distributor Replace valve, shaft, bushing, pin and gasket.
Every 24000 service Major overhaul (complete disassemble and inspection) Replace all O-rings, gaskets and seals.
hours
Inlet and exhaust valves,
valve seat rings,
Replace.
valve guides,
valve rotators, cotters
push rod,
Cylinder head and valve rocker arm bushing,
mechanism valve springs,
tappet rollers,
Check and replace.
tappet shafts,
tappet guides,
Cylinder liner Replace.
Check main bearing caps and bolts. Replace mainbearings
Main bearing
and thrust plates.
Cam bushing Inspect. Replace at the second 24000 hour service.
Piston Disassemble and check piston crown. Replace O-ring.
Connecting rod Replace connecting rod bolts and small end bushing.
Crankshaft Check the journal and pin. Replace the slinger.
Damper Replace at the second 24000 hour service.
Disassemble and service.
Spring coupling
(performed at the spring coupling manufacturer)
Shaft general Inspection
Rear idler gear Inspect and replace gear assembly (including bushings)
Front idler
bearing,
Timing gears and front Camshaft roller
gears bearing,
Front seal, Replace.
Rear seal,
Front gear case
gasket,
Rear gear case gasket
4-14 99089-40100

Every 24000 service Injection nozzle Replace nozzle holder assembly.
hours
Injection pump Replace plunger assembly and delivery valve.
Fuel system Fuel pump
Replace pump assembly.
(trochoid type)
Relief valve Replace.
Oil pump Replace safety valve and snap ring.
Oil thermostat Replace.
Lubrication system
Oil pan Clean and replace gasket.
Relief valve Check and replace.
Water pump Replace shaft and impeller.
Cooling system
Cooling water thermostat. Replace.
Air cooler Replace element at the second 24000 hour service.
Inlet and
Exhaust pipe Check and replace bellows.
exhaust systems
Exhaust duct Replace seal ring.
Actuator
facturer.
Governor
99089-40100
4-15
1. Preparation............................................................................................................... 5-3
1.1 Fuel Supply - Cut Off ................................................................................................................ 5-3
1.2 Coolant - Drain.......................................................................................................................... 5-3
1.3 Engine Oil - Drain ..................................................................................................................... 5-3
99089-40100
5-1
1. Preparation
1.1 Fuel Supply - Cut Off
Before disassembling the engine, close the main fuel

supply valve, and drain fuel from the pipe completely.
If fuel is remaining in the pipe, serious accidents such
as an explosion and fire may result.
Fuel Supply - Cut Off

1.2 Coolant - Drain
(1) Lower the cooling water temperature to 30 to 40°C [86
to 104°F].
(2) Prepare a container to receive the drained water.
(3) Open the drain cocks of engine body, water pumps in
low-temperature system and high-temperature system,
water pipe and expansion tank, and drain cooling water.
Cooling Water Drain Cock (Engine Body)
Cooling water drain cock
Cooling Water Drain Cock (Water Pump)

1.3 Engine Oil - Drain
Oil pan
Be careful not to touch hot oil, or it can cause burns.
Plate
Place a drip pan below the engine oil pan.
Oil pan capacity

Approx. 600L [158.52 US gal.]
Engine Oil - Drain
99089-40100
5-3
1. Cylinder Head and Valve Mechanism - Disassemble and Inspect ...................... 6-3
1.1 Safety Valve and Starting Valve - Remove............................................................................... 6-5
1.2 Fuel Inlet Connector - Remove................................................................................................. 6-5
1.3 Nozzle Assembly - Remove...................................................................................................... 6-6
1.4 Valve Clearance - Inspect......................................................................................................... 6-7
1.5 Fuel Injection Timing - Inspect.................................................................................................. 6-7
1.6 Rocker Arm Assembly and Push Rod - Remove...................................................................... 6-8
1.7 Clearance Between Valve Bridge and Valve Cotter - Inspect .................................................. 6-8
1.8 Cylinder Head Setting Nut -Remove......................................................................................... 6-9
1.9 Cylinder Head Assembly - Remove........................................................................................ 6-11
1.10 Valve and Valve Spring - Remove.......................................................................................... 6-11
1.11 Nozzle Retainer Stud Bolt and Bridge Guide - Remove ......................................................... 6-11
1.12 Copper Tube - Remove .......................................................................................................... 6-12
1.13 Valve Stem Seal - Remove..................................................................................................... 6-12
2. Rear Mechanism - Disassemble and Inspect ...................................................... 6-13
2.1 Flywheel Face and Radial Runouts - Measure....................................................................... 6-16
2.2 Flywheel - Remove ................................................................................................................. 6-16
2.3 Oil Seal - Remove................................................................................................................... 6-16
2.4 Camshaft Bearing and Camshaft Gear Cover - Remove ....................................................... 6-17
2.5 Camshaft Gear Backlash - Measure....................................................................................... 6-17
2.6 Camshaft Gear - Remove....................................................................................................... 6-17
2.7 Timing Gear Case - Remove .................................................................................................. 6-18
2.8 Idler Gear End Play - Measure ............................................................................................... 6-18
2.9 Backlash Between Idler Gear and Crank Gear - Measure ..................................................... 6-18
2.10 Idler Gear and Idler Shaft - Remove....................................................................................... 6-19
2.11 Camshaft - Remove................................................................................................................ 6-19
2.12 Camshaft - Disassemble......................................................................................................... 6-19
3. Front Mechanism - Disassemble and Inspect..................................................... 6-20
3.1 Damper - Remove .................................................................................................................. 6-23
3.2 Oil Seal Retainer - Remove .................................................................................................... 6-24
3.3 Backlash Between Crank Gear and Idler Gear - Measure ..................................................... 6-24
3.4 Front Gear Case - Remove .................................................................................................... 6-24
3.5 Accessory Drive Backlash - Measure ..................................................................................... 6-25
3.6 Waterpump - Remove............................................................................................................. 6-26
3.7 Oil Pump - Remove ................................................................................................................ 6-26
3.8 Idler Gear Backlash - Measure ............................................................................................... 6-26
3.9 Idler Gear - Remove ............................................................................................................... 6-26
3.10 Idler Gear - Disassemble ........................................................................................................ 6-27
4. Cylinder Liner, Piston, and Connecting Rod - Disassemble and Inspect ........ 6-28
4.1 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove ................................... 6-30
4.2 Anti-Polishing Ring - Remove................................................................................................. 6-30
4.3 Connecting Rod Cap - Remove.............................................................................................. 6-31
4.4 Piston - Remove ..................................................................................................................... 6-32
4.5 Piston Ring - Remove............................................................................................................. 6-34
4.6 Piston Pin and Piston - Remove ............................................................................................. 6-34
4.7 Cylinder Liner Inside Diameter - Measure .............................................................................. 6-35
4.8 Cylinder Liner - Remove ......................................................................................................... 6-35
99089-40100
6-1
5. Crankcase, Crankshaft, and Main Bearing - Disassemble and Inspect............ 6-37

5.1 Crankshaft Deflection - Measure ............................................................................................ 6-39
5.2 Crankshaft End Play - Measure.............................................................................................. 6-40
5.3 Oil Pan - Remove ................................................................................................................... 6-41
5.4 Crankcase - Turn Over ........................................................................................................... 6-41
5.5 Main Bearing Cap and lower Main Bearing - Remove............................................................ 6-42
5.6 Crankshaft, Upper Main Bearing and Upper Thrust Plate - Remove...................................... 6-43
5.7 Main bearing replacement without reversing the crankcase................................................... 6-44
6-2 99089-40100
1. Cylinder Head and Valve Mechanism - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to find the cause of trouble and to per-
form efficient maintenance work.
Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with
any job.
Clearance Between Valve Bridge and Valve Cotter - Inspect
Valve Clearance - Inspect
Fuel Injection Timing - Inspect
99089-40100
6-3
Replace Wear,
9
clogging of oil hole
1
Damage on threads 9
7 12
Thread damage, wear 10
8
Wear
Fatigue, damage, 11
Replace slanted position 13
Wear,clogging of oil hole
5 Poor rotation
Wear Wear at both
Piece ends,bend
23
looseness,
6 wear
gas seal face damage 16 15
Replace Replace
Damage, cabon deposition,
Water scale deposition, gas 21 16
seal face damage 14
20
18 Wear of outer
24 Replace
circumference
22 contact face and
Wear
contact face to push
19 Replace 17
rod
Replace
Contact,
Wear 26 Wear
27
21 29
gas seal face damage
Replace
25
4
Replace
Replace
28
Replace
2
3
Replace
Stem, flange face and stem upper position
wear, corrosion, damage and carbon deposition 30
Cylinder Head and Valve Mechanism - Disassemble and Inspect

Disassembly sequence
1 Rocker cover, Screw, Knob, Sealing washer, Gasket 14 Cotter, Upper retainer, spring, Valve rotator
2 Safety valve, Bolt, Washer, Gasket 15 Push rod
(Refer to the chapter "AIR START SYSTEM" for disas- 16 Tappet, Shaft, Roller, Bushing
sembling, inspecting and assembling.) 17 Tappet guide, Set screw, Washer
3 Starting valve, Bolt, Washer, Gasket, O-ring 18 Nut, Stud cap, O-ring
(Refer to the chapter "AIR START SYSTEM" for disas- 19 Cylinder head (Approx. 170 kg [374.8 lb.])
sembling, inspecting and assembling.) 20 Pin, O-ring
4 Fuel inlet connector, O-ring 21 Bridge guide, Stem seal (IN-EX)
5 Nozzle retainer, Bolt, Washer 22 Bridge guide
6 Injection nozzle holder, O-ring 23 Nozzle retainer stud
7 Adjusting screw, Nut 24 Copper tube, Nut, O-ring
8 Contact piece, Snap ring 25 Valve (IN-EX)
9 Bolt, Rocker bracket, Set screw, Nut 26 Valve seat ring (IN-EX)
10 Thrust plate, Snap ring 27 Rubber bushing (air inlet)
11 Rocker arm, Piece 28 Cap, rubber bushing (engine oil), Bolt, washer
12 Rocker shaft, Set screw, Bushing 29 Sealing ring
13 Valve bridge, Set screw, Nut 30 Rubber bushing (cooling water)
6-4 99089-40100
1.1 Safety Valve and Starting Valve - Remove

Remove the safety valve and starting valve. (Refer to the
chapter "AIR START SYSTEM" for disassembling, Starting valve
inspecting and assembling.)
Safety valve
Safety Valve and Starting Valve - Remove

1.2 Fuel Inlet Connector - Remove
Fuel inlet connector

Pay attention not to apply excessive force to the fuel
injection pipe and bend the pipe when removing the
fuel inlet connector. Fuel injection pump
Remove the fuel injection pipe and fuel inlet connector.
Fuel injection pipe

Fuel Inlet Connector - Remove
99089-40100
6-5
1.3 Nozzle Assembly - Remove
Bar
When removing the nozzle holder with nozzle
remover, be careful not to get caught your fingers
between the nozzle remover weight, bar and plate.
Weight
(a)Before removing the nozzle assembly, clean the noz-
zle assembly to prevent foreign material from get-
ting into the cylinder head. Plate
(b)Keep the nozzle and the fuel inlet connector as a set, Weight, Bar and Plate of Nozzle Remover
and handle the nozzle with care to avoid damage to
the nozzle tip.
(1) Using a socket wrench, remove the nozzle retainer set-
ting nut, then remove the nozzle retainer.
Socket
PN: 41091-01200
Mounting nut
Nozzle reatiner
Nozzle holder
Nozzle Retainer - Remove
(2) Remove the nozzle holder with nozzle remover.
Nozzle remover
P/N: 41091-01300
Socket
Nozzle Assembly - Remove
6-6 99089-40100
1.4 Valve Clearance - Inspect

Inspect the valve clearance to check the current condition.
For the inspection procedure, see "Valve Clearance - Inspect
and Adjust" of "ENGINE BODY - ASSEMBLE."
Feeler
gauge
Valve Clearance - Inspect

1.5 Fuel Injection Timing - Inspect
Inspect the fuel injection timing to check the current condi-
tion.
For the inspection procedures, refer to "Fuel Injection Tim-
ing - Check and Adjust" of "ENGINE BODY - ASSEM-
BLE."
Matching mark
Fuel Injection Timing - Inspect
99089-40100
6-7
1.6 Rocker Arm Assembly and Push Rod - Remove

(1) Loosen the adjusting screw of rocker arm.
(2) Remove the bracket retaining bolt with wrench. Bracket
Adjusting screw
(3) Remove the rocker arm assembly with the setting bolt, mounting bolt
and keep them as a set.
(4) Remove the rocker arm assembly, then remove the push
rod.
Push rod
Rocker Arm Assembly and Push Rod - Remove

(5) Disassemble the rocker arm assembly.
Note: Do not remove the rocker bushing unless it is defective
or its inside diameter exceeds the limit.
Place the disassembled rocker arm in the order of as-
sembled sequence to ensure the correct reassembling.
This procedure is for the correct combination of rocker
shaft and rocker arm to secure the clearance before dis-
assembling.
Rocker Arm Assembly - Disassemble

1.7 Clearance Between Valve Bridge and Valve Cotter - Inspect
Inspect the clearance between the valve bridge and valve
cotter, and know the current condition. Valve clearance
For the inspection procedure, refer to "Clearance Between Valve bridge
Valve Bridge and Valve Cotter - Inspect" of "ASSEMBLY Valve cotter
OF BASIC ENGINE."
valve bridge and

valve cotter
Upper retainer clearance
Valve
Clearance Between Valve Bridge and Valve Cotter -

Inspect
6-8 99089-40100
1.8 Cylinder Head Setting Nut -Remove

Remove the cylinder head setting nut with the head hydrau- Head hydraulic jack Hydraulic hose
lic jack, hydraulic hand pump, hydraulic hose and shaft. P/N:41091-04000 P/N: 05312-02100
Note:(a) One of the six cylinder head setting nuts has a stud
Hydraulic hand pump
bolt cap. Remove the cap. P/N: 41091-02001
(b) Before applying the hydraulic pressure to the head
hydraulic jack, loosen the air vent plug of the jack
and bleed air and oil from the jack, retract the jack,
then tighten the air vent plug.
Shaft
P/N: 41091-02600
Cylinder Head Setting Nut -Remove
(a)Apply the hydraulic pressure of six head jacks at a time, and loosen all the six cylinder head setting nuts at a time. If the
nut is loosen one by one, the cylinder head or stud bolt will be damaged.
(b)Before the job, check the hydraulic hose for damage, and each part of the head hydraulic jack and hydraulic hand pump
for oil leak.
(c)Be sure to retract the jack after bleeding air and oil from the jack, then tighten the air vent plug.
(1) Install the foot piece and hydraulic jack of the head
Cylinder head
hydraulic jack. Foot piece mounting stud bolt
Hydraulick jack part
Cylinder head
mounting nut Cylinder head
Head Hydraulic Jack - Install

(2) Tighten fully the tension rod of head hydraulic jack,
turn it back approx 1/3 turn to allow a clearance
Tension rod
between the tension rod and the hydraulic jack.
Clearance
Fully tighten the tension rod, then be sure to turn it

back approx 1/3 turn.
The tension rod will not be removed after releasing the
hydraulic pressure, if the clearance between the ten-
sion rod and hydraulic jack is not provided.
Tension Rod - Install
99089-40100
6-9
(3) Connect the hydraulic hose from the hydraulic hand

pump to hydraulic jack, and apply hydraulic pressure of (Elongation direction) Hose
63.7 MPa {650 kgf/cm2} [9246 psi] to extend the stud
Piston Oil pressure
bolt. Approx. 63.7 MPa
5 mm {650 kgf/cm²}
[0.20 in.] [9246 psi]
Do not extend the head hydraulic jack to exceed the

Stroke limit line
stroke limit (red line) on the periphery of piston rod.
(red line)
The O-ring will be displaced and high-pressure oil will
splash when the head hydraulic jack is extended over
the limit line. This may cause personal injury. Apply Hydraulic Pressure to the Head Hydraulic Jack.
(4) Insert the shaft to the periphery hole of cylinder head
setting nut, and loosen the nut.
Remove the shaft after the nut becomes loose.
Release the hydraulic pressure and remove the head
hydraulic jack.
Shaft
P/N: 41091-02600
Loosen the Cylinder Head Setting Nut.
6-10 99089-40100
1.9 Cylinder Head Assembly - Remove

Install two eye bolts (M12 × 1.75) to the cylinder head, and
lift the cylinder upward.
Note:(a) Befor lifting up the head, install the cover to three Eye bolt
places of tightening stud threads.
(b) Lift up the cylinder head vertical to the cylinder in-
Cover
stalling face of crankcase, and pay attention not to
damage the stud bolt.
Cylinder Head Assembly - Remove

1.10 Valve and Valve Spring - Remove
Compress the valve spring evenly with the valve spring
Valve spring presser
compressor, then remove the valve cotter, upper retainer, P/N: 41091-11400
valve spring, valve rotator and valve.
Note: If valves are reusable, make marks of cylinder number,
inlet or outlet side and cam or anti-cam side to each
Intake port side
valve seat and the mating valve to identify their origi- valve
nal positions. Do not change the combination of the Intake cam side
valve
valve seat and the valve when reassembling.
Exhaust port side valve Exhaust port side valve
Valve and Valve Spring - Remove (1)
Valve cotter Upper retainer
Valve spring
Valve guide
Valve rotator
Valve and Valve Spring - Remove (2)

1.11 Nozzle Retainer Stud Bolt and Bridge Guide - Remove
Do not remove the nozzle retainer stud bolt and the bridge
guide from the cylinder head, unless they are defective.
If they are removed, see "Nozzle Retainer Stud Bolt and
Bridge Guide - Inspect and Replace" of "ENGINE BODY -
INSPECT AND REPAIR"
99089-40100
6-11
1.12 Copper Tube - Remove
Cupper tube
Torque wrench nut wrench
When removing the copper tube with nozzle remover, P/N: 41091-03700
be careful not to get caught your fingers between the
nozzle remover weight, bar and plate. Cylinder head
(1) Remove the copper tube fastening nut with the copper Cupper tube
tube nut wrench. mounting nut
Cupper tube
Copper Tube Fastening Nut -Remove

(2) Install the copper tube removing adapter to the nozzle
Bar
remover, screw it into the upper thread of copper tube
and pull-out the copper tube. Weight
Nozzle remover
P/N: 41091-01300
Plate
Cylinder head
Pull-out
direction
Cupper tube
pull-out adapter
P/N: 41091-08700
Cupper tube
Copper Tube - Remove

1.13 Valve Stem Seal - Remove
Grab the valve stem seal with pliers and remove.
Stem seal
Note: Be sure to replace the valve stem seal with a new one
when assembling the valve and valve spring.
Valve Stem Seal - Remove
6-12 99089-40100
2. Rear Mechanism - Disassemble and Inspect

any job.
Flywheel Face and Radial Runouts - Measure
Idler Gear End Play - Measure
Backlash Between Idler Gear and Crank Gear - Measure
Camshaft Gear Backlash - Measure
99089-40100
6-13
Flywheel and Timing Gear - Disassemble and Inspect
8 Crack,
Dowel pin hole defect
Replace
Flaking,
Wear 8
7
Replace
6 1
4 5
Replace
3
Rotation
Wear
Replace
2
Damage on threads
1
7
6
Crankshaft setting face defect,
crack, dowel pin hole defect,
gear damage, wear Replace
3
Rotation
Replace
Flywheel and Timing Gear - Disassemble and Inspect

1 Flywheel (approx. 212 kg [467.4 lb.]), Bolt, Washer 6 Camshaft gear, Bolt, Washer, O-ring
2 Oil seal case (old type), Oil seal, Packing, Bolt, Washer 7 (1CV-type injection pump, new-type cam spec.)
3 Coverfortachometerinstalling,oilseal,Bolt,Washer,O-ring Camshaft gear, Nut, Spacer
4 Tachometer shaft, Bolt, Washer 8 Timing gear case (approx. 130 kg [286.6 lb.]), Bolt,
5 Bearing Washer, Packing
6-14 99089-40100
Timing Gear and Camshaft - Disassemble and Inspect
㻭
4
Damage, wear
Loosened nut
㻭
2 3
Worn thrust surface
1 Flaking, wear Clogged oil hole,

Damage, wear worn thrust surface
Timing Gear and Camshaft - Disassemble and Inspect

1 Thrust plate, Hexagon socket head bolt (new type), 4 Camshaft (approx. 180 kg [396.8 lb.]),
Bolt (old type), Washer (old type) shaft end (1CV type), Stud, Nut, Dowel pin
2 Idler gear (approx. 30 kg [66.1 lb.]), Bushing
3 Idler shaft, Bolt, Washer
99089-40100
6-15
2.1 Flywheel Face and Radial Runouts - Measure

Measure the face and radial runouts of the flywheel to check
the current condition.
For the measurement procedure, see "Flywheel Face and
Radial Runout - Measure" of "ENGINE BODY - ASSEM-
Dial gauge
BLE."
Flywheel Face and Radial Runouts - Measure

2.2 Flywheel - Remove
(a) Be careful not to drop or hit the flywheel. It can, Flywheel

not only cause damage, but also may cause per- Jack bolt
sonnel injury. (M12×1.75
95mm [3.74 in.] long,
(b) Be careful not to cut your hands with the ring gear
2 pieces)
when pulling-out the flywheel.
Do not use the jack bolt which shows a sharp edge at

the tip. It will damage the crankshaft fitting face. Flywheel - Remove
(1) Install the lifting jig, and lift with a hoist.
(2) Remove the flywheel setting bolt and washer.
(3) Screw in the jack bolts evenly into the jack bolt holes,
and remove the flywheel.
Note: Use the jack bolt with a round end.
2.3 Oil Seal - Remove
Remove the oil seal paying attention not to damage

the seal.
Old type oil seal

(radial type)
the tip. It will damage the timing case fitting face.
In the case of new type oil seal (side seal type)
New type oil seal
Remove the oil seal setting bolt, and remove the oil seal. (side seal type)
In the case of old type oil seal (radial sealing type) Oil Seal - Remove
Screw in the jack bolts (two of the oil seal case tightening
bolts) evenly into the seal case jack bolt holes and remove
the case.
6-16 99089-40100
2.4 Camshaft Bearing and Camshaft Gear Cover - Remove

the tip. It will damage the timing case fitting face.
(1) Remove the cover for tachometer installing and
tachometer shaft.
(2) Screw two jack bolts (M12 × 1.75) into the jack bolt
holes and remove the camshaft gear cover and camshaft
bearing as a set.
(3) Remove spacer.
Note: Use the jack bolt with a round end. Camshaft Bearing and Camshaft Gear Cover -
Remove
2.5 Camshaft Gear Backlash - Measure

Measure the camshaft gear backlash, and know the current
condition. Camshaft gear
For the measurement procedure, refer to "Camshaft Gear
Backlash - Measure" of "ENGINE BODY - ASSEMBLE".
Feeler gauge
Camshaft Gear Backlash - Measure

2.6 Camshaft Gear - Remove
Do not use the jack bolt which shows a sharp edge

at the tip. It will damage the camshaft fitting face.
Remove the camshaft gear mounting nut. Screw two jack
bolts (M10 × 1.25) evenly into the camshaft gear jack bolt
holes, and remove the camshaft gear.
Camshaft Gear - Remove
99089-40100
6-17
2.7 Timing Gear Case - Remove
Be careful not to drop or hit the timing gear case. It

can, not only cause damage, but also may cause per-
sonnel injury.
(1) Instal the lifting jig to the timing gear case and lift with
a hoist.
(2) Remove the timing gear case setting bolt, washer and
remove the timing gear case. Timing gear case
weight: Approx. 130 kg [287 lb.]
Note: Tap the timing gear case with soft head mallet when
the timing gear case can not be removed after remov- Timing Gear Case - Remove
ing all the setting bolts.
2.8 Idler Gear End Play - Measure

Measure the idler gear end play to check the current condi-
tion.
For measurement procedure, see "Idler Gear End Play -
Measure" of "ENGINE BODY - ASSEMBLE".
Idler gear
Idler Gear End Play - Measure

2.9 Backlash Between Idler Gear and Crank Gear - Measure
Measure the idler gear and crank gear backlash, and recog-
Idler gear
nize the current condition.
For the measurement procedure, refer to "Idler Gear and
crank gear backlash - Measure" of "ASSEMBLY OF
BASIC ENGINE. "
Crankshaft
gear
Backlash Between Idler Gear and Crank Gear -

Measure
6-18 99089-40100
2.10 Idler Gear and Idler Shaft - Remove

(1) Place a sling through the rib hole of idler gear and lift
Wire rope
with a hoist.
(2) Loosen the thrust plate setting bolts, and remove the
thrust plate and idler gear from the idler shaft. Camshaft
(3) Remove the idler shaft setting bolt. Screw two jack Idler gear
bolts (M16 × 2) evenly into the idler shaft jack bolt Idler shaft
holes, and remove the idler shaft and washer. Thrust plate
Thrust plate mounting bolt
Idler Gear and Idler Shaft - Remove

2.11 Camshaft - Remove
Camshaft guide Camshaft
P/N: 41091-02900 Wire rope
Carefully pull out the camshaft paying attention to
the cam lobes, journals and bushings to avoid dam-
age.
(1) Install the camshaft guide at the front end of camshaft.
(2) Wind a sling at the rear part of camshaft and lift with a Camshaft weight
(Including camshaft guide)
hoist. Approx. 180 kg [397 lb.]
(3) Move the hoist rearward little by little and pull-out the
camshaft. Engine front Engine rear
Camshaft - Remove
2.12 Camshaft - Disassemble
Pay attention not to damage the cam lobes and jour-

nals when disassembling the camshaft.
Loosen the camshaft connecting nut with a ring wrench and
disassemble the camshaft. Ring wrench
P/N: 41091-08600
Camshaft - Disassemble
99089-40100
6-19
3. Front Mechanism - Disassemble and Inspect

any job.
Damper Face and Radial Runouts - Measure
Backlash Between Crank Gear and Idler Gear - Measure
Accessory Drive Backlash - Measure
Idler Gear Backlash - Measure
6-20 99089-40100
Damper - Disassemble
Replace
Lip face wear, damage,

Deterioration, crack, oil leak 3
Contact mark, deformation, 4
discoloration, dent,
silicone oil leak, crack
Bolt bearing face damage 2
1
2
1
double damper spec
Crack, separation of welded part
Damper - Disassemble and Inspect

1 Damper cover, Rod, Bolt, Nut, Washer 3 Oil seal retainer, Packing
2 Damper (approx. 290 kg [639.3 lb.] max.), Spacer, Dowel Pin, Bolt, 4 Oil seal
Washer
99089-40100
6-21
Accessory Drive - Disassemble
Poor tooth contact, Damage, wear, scuffing

Poor tooth contact,
inside hole scuffing 10 inside hole scuffing
Rotation
Fatigue 7
Rotation 9
8
Rotation
11
6 Rotation
Fatigue
Damage, wear, scuffing
Bearing hole scuffing,
6 local wear, pin hole defect
5
4
3
Damage, wear
Replace scuffing
1
1 Replace
3 1
Crack, dowel pin hole defect,

2 oil pump idler gear housing damage, wear
Accessory Drive - Disassemble and Inspect

1 Front gear case (approx. 115 kg [253.5 lb.]) 4 Idler gear support, Stud, Nut, Washer
Oil pump idler shaft retainer, Pin, Bolt, Washer, O-ring, 5 Retainer, Bolt, Washer
Packing 6 Idler shaft, Bolt, Spacer, Washer
2 Water pump (approx. 32 kg [70.5 lb.]) 7 Idler gear
(Refer to the chapter "COOLING SYSTEM" for disas- 8 Bearing, Spacer, Snap ring
sembling, inspecting and assembling.) 9 Oil pump idler shaft, Bolt, Washer
3 Oil pump (approx. 44 kg [97.0 lb.]) 10 Idler gear
(Refer to the chapter "LUBRICATING SYSTEM" for dis- 11 Bearing, Spacer, Snap ring
assembling, inspecting and assembling.)
Note: Check the rotation, scoring and wear of bearing on disassembly. Replace the bearing with a new one if it is defective.
6-22 99089-40100
3.1 Damper - Remove

Double damper spec.
Upper
Damper dropout
preventive
Do not use the jack bolt which shows a sharp edge stud bolt - Install
at the tip. It will damage the damper fitting face. position
Thread hole
(1) Remove the damper cover. to pull
out damper
(2) Remove two damper setting bolts and washers at sym-
metrically horizontal right and left positions. And
install two damper holding studs (M22 × 1.5, approx. Damper
150 mm [5.91 in.] long). Lower
(3) Remove the remaining damper setting bolts and wash- Installing Position of the Damper Holding Studs.
ers.
(4) Screw two jack bolts (M22 × 1.5) evenly into the front
side damper jack bolt holes. Tighten the bolt to pull out
the damper until a space between the damper back face Damper
and spacer allows the placement of belt shape sling.

(5) Place a belt shape sling at the center of damper and lift
Damper dropout
with hoist. preventive stud bolt
(6) Screw in the jack bolts further and remove the damper (Damper weight:
while lifting it. Approx. 290 kg [639 lb.])
Front Side Damper - Remove
(7) Remove spacer.
(8) Screw two jack bolts (M22 × 1.5) evenly into the rear
side damper jack bolt holes. Tighten the bolt to pull out
the damper until a space between the damper back face
and oil seal retainer allows the placement of belt shape
sling. Spacer
(9) Place a belt shape sling at the center of damper and lift
with hoist.
(10)Screw in the jack bolts further and remove the damper
while lifting it.
(11)Remove the damper holding studs. Spacer - Remove
Note: Place the damper on a pallet or the like. Do not place
the damper directly on the floor.
Damper
Rear Side Damper - Remove
99089-40100
6-23
3.2 Oil Seal Retainer - Remove

at the tip. It will damage the front gear case fitting Oil seal retainer
face. Jack bolt
(1) Fix the lifting jig to the damper cover setting thread Jack bolt
boss. (M12×1.75, 2 pieces)
(2) Remove the oil seal retainer setting nut and washer.
Screw jack bolts evenly into the oil seal jack bolt holes (Oil seal retainer weight:
and remove the oil sear retainer and oil seal as a set. Approx. 65 kg [143 ib.])
Note:(a) Be careful not to damage the oil seal. Oil Seal Retainer - Remove
(b) Use the jack bolt with a round end.
3.3 Backlash Between Crank Gear and Idler Gear - Measure

Measure the crank gear and idler gear backlash, and recog-
nize the current condition.
For the measurement procedure, refer to "Crank Gear and
Idler Gear Backlash - Measure" of "ASSEMBLY OF
ENGINE BODY ".
3.4 Front Gear Case - Remove
Front
gear case
at the tip. It will damage the crankcase fitting face.
(1) Hitch slings to the front gear case. Idler gear
support
(2) Remove the front gear case setting bolt and washer.
Screw two jack bolts (M12 × 1.75) evenly into the front
gear case jack bolt holes and remove the front gear case
Front gear case
with the idler gear support and idler gear as a set. (Including idler gear)
Note: Use the jack bolt with a round end. weight: Approx. 115 kg [254 lb.]
Front Gear Case - Remove
6-24 99089-40100
3.5 Accessory Drive Backlash - Measure

Measure the accessory drive backlash, and know the current condition.
For the measurement procedure, refer to "Accessory Drive Backlash - Measure" of "ENGINE BODY - ASSEMBLE".
A
Crank gear
Damper
Idler gear
Idler gear
Backlash
0.10 to 0.28
[0.004 to 0.011]
Backlash
0.10 to 0.22
[0.004 to 0.009]
B
Water pump gear Backlash B
Backlash
0.10 to 0.28 0.10 to 0.22
[0.004 to 0.011] [0.004 to 0.009]
Backlash
0.10 to 0.22 Backlash
0.10 to 0.22 Water pump
High-temperature [0.004 to 0.009]
[0.004 to 0.009] Water pump gear
circuit
water pump Low-temperature system
water pump
Oil pump idler gear

Oil pump
Oil pump gear
B-B A
Oil pump
A-A
Accessory Drive Backlash - Measure
99089-40100
6-25
3.6 Water Pump - Remove

Remove the water pump from the front gear case.
(Refer to the chapter "COOLING SYSTEM" for disassem-
bling, inspecting and assembling.)
Water Pump - Remove

3.7 Oil Pump - Remove
Remove the oil pump from the front gear case.
(Refer to the chapter "OIL SYSTEM" for disassembling,
inspecting and assembling.)
Oil Pump - Remove

3.8 Idler Gear Backlash - Measure
Measure the idler gear backlash, and know the current con-
dition. Hold an idler gear
For the measurement procedure, refer to "Idler Gear Back-
lash - Measure" of "ENGINE BODY - ASSEMBLE".
Idler Gear Backlash - Measure

3.9 Idler Gear - Remove
Remove the idler gear support fixing nut and washer.
Idler gear
Remove the idler gear support with the idler gear as a set
from the front gear case.
Idler gear
support
Idler gear support weight

(including idle gear): Approx. 43 kg [95 lb.]
Idler Gear Support - Remove
6-26 99089-40100
3.10 Idler Gear - Disassemble

(1) Remove the bolt and washer installed on the idler shaft
Snap ring
and shaft retainer, and remove the shaft retainer and
Spacer
idler shaft.
(2) Remove the idler gear from the idler gear support, and
Bearing
remove the bearing, spacer and snap ring from the idler Idler gear
gear.
(3) Remove the bolt and washer of oil pump idler shaft,
and the bolt and washer of oil pump idler shaft retainer.
Idler shaftࠉ
Remove the oil pump idler shaft, oil pump idler gear
Shaft retainer
and oil pump idler shaft retainer.
Idler Gear - Disassemble
(4) Remove the bearing, spacer and snap ring from the oil
pump idler gear. Oil pump idler shaft
Oil pump idler gear
Snap ring
Spacer
Bearing
Shaft retainer
Oil Pump Idler Gear - Disassemble
99089-40100
6-27
4. Cylinder Liner, Piston, and Connecting Rod - Disassemble and Inspect

any job.
Cylinder Liner Inside Diameter - Measure
6-28 99089-40100
5
6
Wears, scratches,
7 damages, flaking
8 Scratches on outer surface,

cracks, damage, wear,
12
carbon deposits
Replace
Fatigue Scratches on outer surface,

cracks, damage, wear,
carbon deposits
13
10 Anti-polish
Wears Damage on gas seal face ring
9 11 Damaged threads, wear, faulty

matching of collar and piston body
Scratches on inside surface, wear,

15 rust, defect on outer periphery
14
Cracks, clogged oil hole,

Replace
damaged threads
Wear on inside 16
surface
4
Replace after 17
inspection
Cracks, damage,
3
score on seating surface
Damaged threads
(11 mm [0.43in.] serration type)
1 2
Scores on
seating surface
Cylinder Liner, Piston, and Connecting Rod - Disassemble and Inspect

1 Bolt (long), Washer 10 Piston pin
2 Bolt (short), Washer 11 Bolt, Collar
3 Connecting rod cap 12 Piston crown, O-ring
4 Lower connecting rod bearing 13 Piston body (approx. 25 kg [55.1 lb.]), Spring pin
5 No. 1 compression ring 14 Connecting rod (approx. 31 kg [68.3 lb.])
6 No. 2 compression ring 15 Piston pin bushing
7 No. 3 compression ring 16 Upper connecting rod bearing
8 Oil ring 17 Cylinder liner (approx. 65 kg [143.3 lb.]), O-ring
9 Snap ring
99089-40100
6-29
4.1 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove
Be sure to remove hard carbon deposits from the

upper part of the cylinder liner before removing the pis- Cylinder liner
ton. Hard carbon deposits, if not removed, cause dam-
age to the piston and piston rings.
Remove hard carbon deposits from the upper part of cylin-
der liner with carbon remover (scraper, sandpaper, etc.)
Note: Be careful not to damage the inner surface of the cyl-
Waste cloth, oil paper
inder liner.
Hard Carbon Deposits on the Upper Part of Cylinder
Liner - Remove
4.2 Anti-Polishing Ring - Remove

When the liner is installed with an anti-polishing ring,
remove the anti-polishing ring before pull out the piston.
Remove the anti-polish ring as the procedure below.
4.2.1 Anti-Polish Ring and Carbon in the Cylinder

Liner Upper Position - Remove
If carbon deposits are seen around the anti-polish ring and
cylinder liner upper position, remove the carbon with waist
cloth or oil paper before pulling-out the piston. Or the anti-
polish ring then the piston may be hard to pull-out upward.
Note: Pay attention not to cause scratches on the cylinder in-
side face.
4.2.2 Anti-Polishing Ring Remover - Install

Insert anti-polish ring remover plates (4 places) to anti-pol- Nozzle remover
P/N: 41091-03100
ish ring pull-out grooves. Fix the anti-polish ring remover at
Plate
the position free from looseness to the anti-polish ring. Then
install the nozzle remover on top of the anti-polish ring
remover. Anti-polishing
Remover
P/N: 41091-09000
Cylinder liner
Anti-Polishing Ring Remover - Install

4.2.3 Anti-Polishing Ring - Remove
Pay attention not to pinch your hand when the nozzle

remover moves up and down.
Move the nozzle remover handle up and down, and gradu-

ally pull out the anti-polish ring.
6-30 99089-40100
4.3 Connecting Rod Cap - Remove

4.3.1 Piston Remover hanger - Install
Wire
Install the piston remover hanger on the top face of piston Piston
Hanger
crown, and support the piston with a sling and hoist above remover
P/N:
to prevent the piston and connecting rod from falling when Bolt 41091-10600
the connecting rod cap is removed.
Piston Remover hanger - Install

4.3.2 Connecting Rod Cap - Remove
Using a socket wrench, remove the connecting rod bolt and
washer through the inspection window on the side of the
crankcase, and remove the connecting rod cap.
Note:(a) Pay attention not to drop the connecting rod bearing
into the oil pan and damage the bearing.
(b) Make marks, such as cylinder number and upper or
lower, on the removed connecting rod bearings to
Socket
ensure the correct reassembly. P/N: 41091-09900
(c) Pay attention to the weight (approx 16 kg [35 lb]) of (Seen from the engine front)
Connecting Rod Cap - Remove
connecting rod cap and not to drop the cap when it
is removed.
99089-40100
6-31
4.4 Piston - Remove
When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer
from hand injury by an accidental movement of connecting rod.
(a) When pulling-out the piston, be careful not to drop the upper connecting rod bearing. Dropping the upper con-
necting rod bearing will cause damage to the cylinder liner and the crankshaft.
(b) When removing the piston, be careful not to damage the cylinder liner with connecting rod movement.
(c) When only a few pistons remain in the cylinders, the crankshaft tends to turn by weight imbalance. Be sure to
hold the crankshaft to prevent it from rotating while removing pistons.
(1) Remove the connecting rod cap and turn the crankshaft
to bring the piston to the top dead center position.
Note:(a) Check the compression top dead center position Pointer
with the pointer and flywheel stamp mark installed
at the rear end, then visually check the position.
(b) Adjust the lifting sling tension as required to pre-
vent the piston and connecting rod from falling Cylinder No. punch mark
when the crankshaft is rotated.
(Seen from the engine rear)

Crankshaft Top Dead Center (Right Bank)
(2) Install the guide piece of piston remover to the connect-
ing rod big end thread with bolt to prevent the connect-
ing rod sharp edge from damaging the cylinder liner
inner face when pulling-out the piston. Guide piece
Piston remover
Bolt P/N: 41091-10600
Guide Piece - Install
6-32 99089-40100
(3) Turn the crankshaft slowly while lowering the piston

slowly with a hoist, and separate the connecting rod
from the crank pin.
Note:(a) Turn the crankshaft approx. 30° in reverse to pull
out the piston in the right bank, and in forward in
the case of the left bank.
(b) Pay attention not to damage the crank pin when sep-
arating the connecting rod from the crank pin.

Piston -Pull Out (1) (Right Bank)
(4) Place the guide piece to contact the cylinder inside face
while lifting the piston slowly.
Lift the piston and connecting rod and pull out from the
cylinder liner. Place the guide
piece to contact
Note:(a) Place the removed piston, piston pin, connecting
the cylinder liner.
rod and connecting rod cap, not on the ground di-
rectly but on the pallet or the like.
(b) Keep removed pistons, piston pins, connecting rods
and connecting rod caps as a set according to cylin-
der numbers and mark each of them with the appro-
Piston -Pull Out (2) (Right Bank)
priate cylinder number. When the parts are
assembled, be sure to use them in the same cylin-
ders as before. Do not use them in another cylinder.
Removed Piston - Store
99089-40100
6-33
4.5 Piston Ring - Remove
When removing the piston ring, be careful not to be pinched your hand between the piston and connecting rod by
the piston tilt movement.
A free swing of piston and its bump to connecting rod may result in piston body damage.
Hold the piston and connecting rod in a vise, and remove
the piston rings with piton ring pliers.
Piston ring plier

P/N: 41091-12400
Piston Ring - Remove

4.5.1 Pliers - Set
No. 1 Compression Ring - Remove
(1) Place the R mark tip to right side.
(2) Place the L mark tip to left side.
No. 2 and 3 Compression Rings - Remove
Place tips without mark to both sides.
4.6 Piston Pin and Piston - Remove
(1) Hold the piston and connecting rod in a vise, install the
Piston remover
piston remover hanger to the top face threads with bolts P/N: 41091-10600
and suspend the piton with a hoist. Snap ring
(2) Remove the snap ring with snap ring pliers.
(3) Place a piece of wood to piston pin end and lightly tap Snap ring pliers
with hammer to remove the piston pin, and separate the
piston from connecting rod.
Note:(a) Do not tap the piton pin directly with hammer.
(b) If the piston is stubborn, heat the piston with a pis-
ton heater or in hot water.
Snap Ring - Remove
Support plate
Hammer
Piston Pin and Piston - Remove
6-34 99089-40100
4.7 Cylinder Liner Inside Diameter - Measure

Measure the cylinder liner inside diameter to check the cur-
rent condition.
For measurement procedure, see "Cylinder Liner Inside
Diameter - Measure" of "ENGINE BODY - ASSEMBLE".
Cylinder Liner Inside Diameter - Measure

4.8 Cylinder Liner - Remove
Use the cylinder liner remover to remove and install the cyl-
Jack bolt Cylinder head
inder liner. stud bolt
Cylinder head
4.8.1 Cylinder Liner - Remove with Wrench Adapter A
mounting nut
(1) Install the plate A and block on the top face of cylinder,
Hanger bolt
and plate B on the bottom face with the stud bolt and Plate C
nut. Pipe
Stud bolt
(2) Place three pipes to equally spaced three cylinder head Plate A
stud bolts, and place the plate C on the pipes and hand
Block
tighten the nuts. Nut
Plate B
(3) Apply MOLYKOTE (molybdenum disulfide anti-seize)
Cylinder Liner - Remove with Wrench
or equivalent to the jack bolt thread.
(4) Install the adapter A to the jack bolt, and screw into the
Hanger bolt
block with wrench to pull-out the liner.
(5) Remove the jack bolt, adapter, head setting nuts, plate
Lift with a sling.
C and pipes.
(6) Hitch a sling to the hanger and lift with hoist.
Lifting direction
Cylinder Liner - Lift
99089-40100
6-35
4.8.2 Cylinder Liner - Remove with Hydraulic Jack

Adapter B Hydraulic jack
(When the Removal with Wrench Is Difficult.) P/N: 41091-04100
(1) Install the plate A and block on the top face of cylinder, Jack bolt Plate C
and plate B on the bottom face with the stud bolt and
Adapter A Cylinder head
nut. stud bolt
(2) Place three pipes to equally spaced three cylinder head Sleeve
stud bolts, and place the plate C on the pipes and hand Nut
Cylinder head
tighten the nuts. 3m mounting nut
Hanger bolt m
(3) Install the sleeve and nut, and screw the jack bolt and [0.
12
in.
adapter A into the block until it contacts with the Plate ]
Pipe
C.
(4) Tighten the nut to fix the sleeve.
Plate A
(5) Set the hydraulic jack on the adapter A with the adapter
B. Apply a hydraulic pressure with the hydraulic jack Block
until the liner moves up, and remove the liner.

Nut Stud bolt
Max operating pressure of 63.7 MPa
hydraulic jack {649.6 kgf/cm2}[9238.9 psi] Plate B Cylinder liner weight: Approx 65 kg [143 lb.]
Max allowable stroke 5 mm [0.20 in.] Cylinder Liner - Remove with Hydraulic Jack
Note: Remove the tension rod and foot piece from the head
jack (41091-04000) to make the hydraulic jack
(41091-04100).
(6) Remove the adapter B, hydraulic jack, adapter A,
sleeve, nut, head setting nuts and pipes.
(7) Hitch a sling to the hanger and lift with hoist.
6-36 99089-40100
5. Crankcase, Crankshaft, and Main Bearing - Disassemble and Inspect

any job.
Crankshaft Deflection - Measure
Crankshaft End Play - Measure
99089-40100
6-37
Wate scale deposition, damage, crack,

corrosion, oil hole clogging, wear Rear
Thread damage, bend

Replace
Inside face flaw, wear

Replace with a new one 2
when disassembled. Replace with
a new one
when weared
Replace or disassembled.
16
8
Front Dent, damage, wear
Thread damage 13 12
Inside/outside face damage, 15
corrosion, flaking
Replace with a new one Replace 5 Flaking, wear,
when disassembled. 9 tooth contact, looseness
Loose oil hole plug

Replace with
7 a new one
Scratch, crack, dent, 4
oil hole clogging, wear when weared
or disassembled.
Dent, damage, wear, 10
looseness 11
Replace
6
Flaking, wear, tooth contact, 1
looseness
Inside/outside face damage,

corrosion, flaking 3 Strainer clogging
Replace with a new one
when disassembled.
Replace
1
Corrosion, crack, damage Crack
Crankcase, Crankshaft, and Main Bearing - Disassemble and Inspect

Removal sequence
1 Oil pan (approx. 380 kg [837.8 lb.]), Gasket, Strainer, Cover, 9 Upper main bearing
Bolt, Washer, O-ring 10 Front clinger
2 Side bolt, Washer, O-ring 11 Front crank gear
3 Nut 12 Rear clinger
4 Main bearing cap (approx. 37 kg [81.6 lb.]) 13 Rear crank gear
5 Lower thrust plate 14 Set screw, gasket
6 Lower main bearing 15 Camshaft bushing
7 Crankshaft (approx. 1500 kg [3306.9 lb.]) 16 Crankcase, Cylinder head setting stud, Mounting bracket,
8 Upper thrust plate Bolt, Washer
6-38 99089-40100
5.1 Crankshaft Deflection - Measure

Measure the deflection of crankshaft at the time of over-
hauling, before disassembling and after assembling.
Note: Measure the deflection with the driven equipment such
as a generator installed at the flywheel end.
7 mm
[0.28 in.] 11 mm
5.1.1 Crankshaft Deflection - Measuring Procedure [0.43 in.]
The measuring procedure and instrument vary with the dif- 9 mm
ference of connecting rod serration. [0.35 in.]
7 mm [0.28 in.] and 11 mm [0.43 in.]
9 mm [0.35 in.] pitch serration pitch serration
Serration on Connecting Rod

5.1.2 Setting position of deflection gauge
Unit: mm [in.]
Place on the balance weight at the 130 mm position from the Web Deflection gauge
crankshaft center. P/N: 41291-10100
Applicable connecting rod assembly num-

41019-60100
ber
130 [5.12]
160 [6.30]
Balance weight Crankshaft center

Setting Position of Deflection Gauge
5.1.3 Procedure of deflection measurement
Start from the 1 in the illustration right, turn the crankshaft
and measure the amount of change in the sequence of 2, 3, 4
and 5.
The difference between the largest and smallest readings is
1 50°
the deflection of the throw.
Align the engine and driven equipment, if the crankshaft 2 50°
deflection exceeds the standard value. 5
Item Standard value 4

11 mm [0.43 in.]-pitch 3
0.029 mm
Crankshaft deflection serration connecting
[0.0011 in.] or less Procedure of Deflection Measurement
rod
99089-40100
6-39
5.2 Crankshaft End Play - Measure

Tighten the rearmost bearing cap nuts and side bolts in the +0.035
100 ( 0 ) mm
proper procedure. Then measure the end play (clearance
+0.0014
[3.94 ( 0 ) in.]
between the width of crankshaft thrust bearing faces and the

width of thrust plates installed on the bearing cap) of the
crankshaft.
(1) Apply the dial gauge plunger to the rear end face of
crankshaft.
(2) Insert two bars from both sides to the clearance
between the crankshaft balance weight and the crank-
case through the rearmost crankcase inspection win-
Crankshaft Thrust Bearing Face
dows.
(3) With the bars, move crankshaft fully to front and rear,
and read each measurement. The end play is the differ-
ence between the front and rear measurements. Replace
Thrust plate
the thrust plates if the end play of crankshaft exceeds -0.19
9(-0.22 )
-0.0075
the limit. [0.35(-0.0087 )] -0.19 -0.0075
9(-0.22 ) [0.35(-0.0087 )]
Main bearing cap
82( )
0
-0.035
(rearmost end)
Measurement item Standard value Limit value 0
[3.22( -0.0014 )]
0.38 to 0.51 mm 0.60 mm -0.380 -0.015
100(-0.475 ) [3.94(-0.019 )]
Crankshaft end play
[0.0150 to 0.0201 in.] [0.0236 in.]
Unit: mm [in.]
(4) If the limit is still exceeded after installing the new Dimensions Around Thrust Plate
thrust plates, use the oversize thrust plates.
Note:(a) Three over sizes of +0.25, +0.50 and +0.75 mm
[+0.0098, +0.0197 and +0.0295 in.] are provided.
(b) In general, the rear thrust plates wear faster than the
front thrust plates. Therefore, in most cases, the cor-
rection is achieved by replacing the rear thrust
plates with a next oversize ones.
(5) If the end play becomes smaller than the standard value
with the oversize thrust plates, re-grind the thrust bear-
ing surface of crankshaft and use the oversize thrust Bar
plates. Crankshaft End Play - Measure
Re-grinding dimensions of crankshaft thrust bearing face

Over size Over size
Over size plate on one plates on Tolerance
side both sides
+0.25 100.25 mm 100.50 mm
[0.0098] O.S [3.9468 in.] [3.9567 in.]
+0.50
100.50 mm 101.00 mm +0.035 +0.0014
[+0.0197 in.]
[3.9567 in.] [3.9764 in.] 0 mm [ 0 in.]
O.S
+0.75 100.75 mm 101.50 mm
[0.0295 in.] O.S [3.9665 in.] [3.9961 in.]
6-40 99089-40100
5.3 Oil Pan - Remove

Support the oil pan with a jack or hoist. Remove the oil pan
setting bolt. Then remove the oil pan. Oil pan weight
Approx. 380 kg [838 lb.]
Rear
Crankcase
Gasket for
oil pan
Front
Oil pan
Oil pan mounting bolt
Oil Pan - Remove

5.4 Crankcase - Turn Over
Place the crankcase on the turn over machine. Then reverse
the crankcase.
99089-40100
6-41
5.5 Main Bearing Cap and lower Main Bearing - Remove

Remove the side bolt from the reversed crankcase. Remove
Cap hydraulic jack
the main bearing cap nut with the hydraulic jack, hydraulic P/N: 41091-03500 Hydraulic hose
hand pump, hydraulic hose and shaft. Air vent plug P/N: 05312-02100
Shaft
Note: Before applying the hydraulic pressure to the cap hy- P/N: 41091-02600 Hydraulic hand pump
draulic jack, loosen the air vent plug of the jack and P/N: 41091-02001
bleed air and oil from the jack, retract the jack, then
tighten the air vent plug.
Main Bearing Cap Nut - Remove
(a) Apply the hydraulic pressure to two cap hydraulic jacks at a time, and remove the two main-bearing cap nuts
at a time. If the nut is removed one after the other, uneven tightening will damage the main bearing or stud.
(b) Before the job, check the hydraulic hose for damage, and each part of the cap hydraulic jack and hydraulic
hand pump for oil leak.
(c) Be sure to retract the jack after bleeding air and oil from the jack, then tighten the air vent plug.
(1) Place the foot piece of cap hydraulic jack, fully tighten
the hydraulic jack (with piston rod) then turn it back Piston rod
approx. 1/3 turn to make a clearance between the foot Hydraulick jack part
P/N: 41091-03500 Main bearing
piece and hydraulic jack. stud bolt
Foot piece
Main bearing
Fully tighten the piston rod, then be sure to turn it cap setting nut
Main bearing cap
back approx. 1/3 turn.
The hydraulic jack will not be removed after releas-
ing the hydraulic pressure, if the clearance between
the foot piece and hydraulic jack is not provided. Cap Hydraulic Jack - Install
(2) Connect the hydraulic hose from the hydraulic hand Hydraulic pressure Hydraulic hose
pump to hydraulic jack, and apply hydraulic pessure of 63.7 MPa {650 kgf/cm2} P/N: 05312-02100
[9246 psi]
63.7 MPa {650 kgf/cm2} [9246 psi] to extend the stud. Stroke limit line
(Red line) (Elongation
Approx. direction)
5 mm [0.2 in.]
Do not extend the cap hydraulic jack to exceed the Hydraulic hand pump
P/N: 41091-02001
splash when the cap hydraulic jack is extended over
the limit line. This may cause personal injury.
Apply Hydraulic Pressure to the Cap Hydraulic Jack.
6-42 99089-40100
(3) Insert the shaft to the periphery hole of main bearing

cap nut, and loosen the nut.
Release the hydraulic pressure and remove the cap Shaft
P/N: 41091-02600
hydraulic jack.
(4) After removing the cap jack, install an eye bolt (M12 ×
1.75) to the main bearing cap and pull out the cap
upward with a hoist.
Remove the main bearing cap paying attention not Loosen the Main Bearing Cap Nut.
damage the lower main bearing or lower thrust plate
Main bearing cap
attached to the cap. Also be careful not to drop those Front
parts, which may damage the crankshaft.
(5) Remove the lower main bearing from the main bearing
cap paying attention to the lug location. Remove the
lower thrust plate from the rearmost (No. 9) main bear-
ing cap. Lower
thrust plate
Lower main bearing Rear
Main Bearing Cap - Remove

5.6 Crankshaft, Upper Main Bearing and Upper Thrust Plate - Remove
Crankshaft
(a) When placing the crankshaft onto a pallet or Crankshaft Upper thrust plate
other stands, be careful not to damage the assembly weight
1690 kg [3726 lb.]
crankshaft. Once placed on a pallet, the crank-
shaft should be locked in place to prevent it from
rotating.
(b) The thrust plate can be removed or replaced Rear
only when the rearmost (No. 9) main bearing cap

and crankshaft are completely removed from the Front
crankcase. Crankshaft, Upper Main Bearing and Upper Thrust
Plate - Remove
(1) Suspend the crankshaft in a horizontal position, and
slowly lift the crankshaft upward.
Note: Do not attach a metal chain or other hoisting devices
directly onto the crankshaft, as they could damage the
crankshaft. Place cloth belts or pads in position where
a chain or other hoists are hooked before raising crank-
shaft.
(2) After removing the crankshaft, remove the upper main
bearing from the crankcase and remove the upper thrust
plate from the rearmost (No. 9) main bearing.
99089-40100
6-43
5.7 Main bearing replacement without reversing the crankcase

Replace the main bearings upper and lower as a set when
the main bearing cap is removed.
(a) Divide the removal of main bearing caps and

replacement of main bearings to two times by
separating the job in two steps. First step: No. 1,
3, 5, 7 and 9. Second step: No. 2, 4, 6 and 8. If all
the main bearing caps are removed in one time,
the crankshaft will fall. The result can be the
crankshaft damage and may be personal injury.
(b) Be sure to prepare a support table and hydraulic
jack to prevent the main bearing cap from falling.
If the main bearing cap falls, the result can be the
oil pan damage and may be personal injury.
(1) Remove the side bolt which tightens the main bearing
cap.
(2) Place a support table and hydraulic jack in the oil pan
beneath the main bearing cap, and support the main
bearing cap.
Hydraulic jack
Support table
Support Table and Hydraulic Jack - Place

(3) Main Bearing Cap - Remove the main bearing cap nut
with the cap hydraulic jack, hydraulic hand pump,
Hydraulic hose
hydraulic hose and shaft.
P/N: 05312-02100
Note: Before applying the hydraulic pressure to the cap hy-
draulic jack, loosen the air vent plug of the jack and Hydraulic hand pump
bleed air and oil from the jack, retract the jack, then P/N: 41091-02001

Cap hydraulic Hydraulic hose
pressure jack P/N: 05312-02100
P/N: 41091-03500
Main Bearing Cap Nut - Remove
6-44 99089-40100
(a)Place the foot piece of cap hydraulic jack, fully tighten

the hydraulic jack (with piston rod) then turn it back
Main bearing
approx. 1/3 turn to make a clearance between the foot Main bearing
cap
piece and hydraulic jack. cap setting
Foot piece nut
Main bearing
stud bolt
Fully tighten the piston rod, then be sure to turn it Hydraulick jack part
back approx. 1/3 turn. Piston rod
The hydraulic jack will not be removed after releas- Upper
Lower
ing the hydraulic pressure, if the clearance between
the foot piece and hydraulic jack is not provided. Cap Hydraulic Jack - Install
(b)Connect the hydraulic hose from the hydraulic hand
pump to hydraulic jack, and apply hydraulic pressure
of 63.7 MPa {650 kgf/cm2} [9246 psi] to extend the
stud.
Approx 5mm
[0.2 in.]
(Elongation
Do not extend the cap hydraulic jack to exceed the direction)
Stroke limit line
(Red line)
Upper Hydraulic pressure
The O-ring will be displaced and high-pressure oil will Hydraulic hose 63.7 MPa {650 kgf/cm2}
Lower P/N: 05312-02100 [9246 psi]
splash when the piston rod is extended over the limit
line. This may cause personal injury. Apply Hydraulic Pressure To The Cap Hydraulic Jack.
(c)Insert the shaft to the periphery hole of main bearing

cap nut, and loosen the nut.
Release the hydraulic pressure and remove the cap
hydraulic jack.
Shaft
Upper
Lower
Loosen the Main Bearing Cap Nut.

(4) Retract the hydraulic jack supporting the main bearing
cap, and lower the main bearing cap by 100 mm [3.94
in.] or more (max 330 mm [12.99 in.]). 100 mm
[ 3.94 in]
(5) Remove the lower main bearing from the main bearing or more
cap.
(6) Remove foreign material and contamination of oil from
the bearing housing face of main bearing cap. Apply Lower main bearing
clean oil evenly to the bearing inside face. Place the
new lower main bearing to the main bearing cap. Main bearing cap
Lower the Main Bearing Cap.
99089-40100
6-45
(7) Place the main bearing removing pin into the crankshaft
Crankcase Upper main bearing
oil hole placing the flat face of the pin to the upper
main bearing.
Turning direction
(8) Turn the crankshaft slowly in counterclockwise direc-
tion seen from the engine rear to remove the upper main Lug slot
bearing.
(9) Remove foreign material and contamination of oil from Lug
the bearing housing face of main bearing. Apply clean Main bearing
Crankshaft removing pin
oil evenly to the new upper bearing inside face. Insert P/N: 41091-11800
the bearing between the crankcase and crankshaft from (Seen from the engine rear)
Upper Main Bearing - Remove
the lug slot side.
(10)Turn the crankshaft slowly in clockwise direction seen
Crankcase Upper main bearing
from the engine rear to push in the upper main bearing
with the main bearing removing pin.
Turning direction
(11)Stop the turning when the lug of upper main bearing fit
to the crankcase lug slot. Lug slot
Lug Pin
Pin Crankshaft
Upper Main Bearing - Install
(a) Do not apply oil and the like to the bearing outside face and bearing housing faces of crankcase and main
bearing cap when installing the main bearing.
(b) Pay attention not to drop the bearing when replacing the bearing.
(c) Pay attention to the crankshaft turning direction when removing and installing the bearing. The main bearing
has a positioning lug. The main bearing lug and lug slot can be damaged when the turning direction is wrong.
(12)Extend the hydraulic jack supporting the main bearing
cap, and place the main bearing cap to the proper posi- Left side bolt Right side bolt
392 N·m 196 N·m
tion. Apply Moly LG Grease No. 2 (SUMICO) or {40 kgf·m} {20 kgf·m}
equivalent to the threads of main bearing stud bolt. [289 lbf·ft] [145 lbf·ft]
Hand tighten the main bearing cap nut.
(13)Apply Moly LG Grease No. 2 (SUMICO) or equivalent
to the threads of side bolt, and install the washer and
new O-ring.
(14)Temporarily tighten the left side bolt seen from the rear
to the specified torque.
Side Bolt - Tighten Snugly
(15)Temporarily tighten the right side bolt seen from the
rear to the specified torque.
6-46 99089-40100
(16)Remove the main bearing cap nut with the hydraulic

jack, hydraulic hand pump, hydraulic hose and shaft. Hydraulic hose
Note: Before applying the hydraulic pressure to the cap hy- P/N: 05312-02100
bleed air and oil from the jack, retract the jack, then P/N: 41091-02001
Cap hydraulic Hydraulic hose

pressure jack P/N: 05312-02100
P/N41091-03500
Main Bearing Cap Nuts - Install
(a)Install the foot piece of cap hydraulic jack, and fully
tighten the hydraulic jack (with the piston rod).
Main bearing
cap Main bearing
cap setting
Foot piece nut
Main bearing
stud bolt
Piston rod
Upper
Lower
Cap Hydraulic Jack - Install

(b)Connect the hydraulic hose from the hydraulic hand
pump to hydraulic jack, and apply hydraulic pressure
of 63.7 MPa {650 kgf/cm2}[9246 psi] to extend the
stud.
Approx.
5 mm [0.2 in.]
Do not extend the cap hydraulic jack to exceed the (Elongation
Stroke limit line
direction)
stroke limit (red line) on the periphery of piston rod. (Red line)
Upper Hydraulic pressure
The O-ring will be displaced and high-pressure oil will Hydraulic hose 63.7 MPa {650 kgf/cm2}
Lower
splash when the cap hydraulic jack is extended over P/N: 05312-02100 [9246 psi]
the limit line. This may cause personal injury. Apply hydraulic pressure to the cap hydraulic jack.
99089-40100
6-47

cap nut, and snug tighten the nut to the main bearing
cap.
Remove the shaft, release the hydraulic pressure, and
remove the cap hydraulic jack.
Shaft
P/N: 41091-02600
Upper
Lower

(17)Tighten the left side bolt seen from rear to the specified
torque. Then tighten the right side bolt seen from rear to 883 N·m 883 N·m
{90 kgf·m} {90 kgf·m}
the specified torque.
[651 lbf·ft] [651 lbf·ft]
(18)Remove the support table and hydraulic jack which
supported the main bearing cap.
Side Bolt - Tighten
6-48 99089-40100
1. Cylinder Head and Valve Mechanism - Inspect and Repair................................. 7-3
1.1 Rocker Bushing Inside Diameter and Rocker Shaft Outside Diameter - Measure ................... 7-3
1.2 Rocker Bushing - Replace ........................................................................................................ 7-3
1.3 Nozzle Retainer Stud and Bridge Guide - Inspect and Replace............................................... 7-3
1.4 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure ........................... 7-4
1.5 Valve Guide - Replace.............................................................................................................. 7-4
1.6 Valve Face - Inspect ................................................................................................................. 7-5
1.7 Valve Face - Reface ................................................................................................................. 7-6
1.8 Valve Seat Ring - Reface ......................................................................................................... 7-6
1.9 Valve Seat Ring - Replace........................................................................................................ 7-7
1.10 Valve and Valve Seat Ring - Lap.............................................................................................. 7-8
1.11 Bridge, Valve Stem Upper Portion, Bridge Guide and Valve Rotator - Inspect ........................ 7-8
1.12 Squareness and Free Length of Valve Spring - Measure......................................................... 7-8
1.13 Clearance Between Tappet Guide Set Screw Hole and Set Screw - Check ............................ 7-9
1.14 Tappet and Tappet Guide - Measure...................................................................................... 7-10
1.15 Pushrod Runout - Measure..................................................................................................... 7-10
1.16 Cylinder Head Gas Sealing Face - Reface............................................................................. 7-11
2. Rear Mechanism - Inspect and Repair................................................................. 7-13
2.1 Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure .......................... 7-13
2.2 Cam Lift -Measure .................................................................................................................. 7-13
2.3 Camshaft Runout - Measure................................................................................................... 7-13
2.4 Camshaft Journal Outside Diameter - Measure ..................................................................... 7-14
2.5 Camshaft Bushing - Inspect and Replace .............................................................................. 7-14
3. Front Mechanism - Inspect and Repair................................................................ 7-16
3.1 Damper - Inspect .................................................................................................................... 7-16
3.2 Sampling of silicone oil from the damper................................................................................ 7-16
3.3 Silicone Oil Property Check .................................................................................................... 7-19
3.4 Damper Temperature Control................................................................................................. 7-19
3.5 Visual Inspection of Accessory Drive...................................................................................... 7-20
3.6 Dimensional Measurement of Accessory Drive ...................................................................... 7-21
4. Cylinder Liner, Piston and Connecting Rod - Inspect and Repair .................... 7-24
4.1 Cylinder Liner Gas Sealing Face - Reface ............................................................................. 7-24
4.2 Clearance Between Cylinder Liner and Cylinder Head - Check ............................................. 7-26
4.3 Piston - Check ........................................................................................................................ 7-26
4.4 Piston - Disassemble .............................................................................................................. 7-27
4.5 Piston Ring Groove Clearance - Measure .............................................................................. 7-28
4.6 Clearance Between Piston Pin Bore and Piston Pin Diameter............................................... 7-28
4.7 Standard for Piston Ring Replacement .................................................................................. 7-29
4.8 Piston Pin - Check .................................................................................................................. 7-30
4.9 Connecting Rod - Inspect ....................................................................................................... 7-30
4.10 Connecting Rod Big End Thread Hole - Roll .......................................................................... 7-31
4.11 Connecting Rod Cap and Connecting Rod Bolt - Inspect....................................................... 7-32
4.12 Connecting Rod Bearing - Inspect and Replace..................................................................... 7-33
4.13 Connecting Rod Big End Bearing Housing - Inspect and Repair ........................................... 7-33
4.14 Connecting Rod Bearing Inside Diameter - Measure ............................................................. 7-34
4.15 Inside Diameter of Piston Pin Bushing - Measure .................................................................. 7-34
4.16 Piston Pin Bushing - Replace ................................................................................................. 7-35
4.17 Weight Difference of Connecting Rod Assembly in One Engine ............................................ 7-35
99089-40100
7-1
5. Crankcase, Main Bearing and Crankshaft - Inspect and Repair ....................... 7-36
5.1 Slinger and Crank Gear - Inspect and Replace ...................................................................... 7-36
5.2 Crank Pin and Journal Outside Diameters - Measure ............................................................ 7-40
5.3 Crankshaft - Grind .................................................................................................................. 7-41
5.4 Crankshaft Runout - Measure................................................................................................. 7-42
5.5 Crankshaft Oil Hole Plug Looseness - Check......................................................................... 7-42
5.6 Crankcase, Main Bearing Cap Contacting Face - Check ....................................................... 7-42
5.7 Main Bearing - Inspect and Replace....................................................................................... 7-43
5.8 Crankcase, Main Bearing Housing Face - Disassemble and Inspect..................................... 7-43
5.9 Crankcase Main Bearing Housing Diameter - Measure ......................................................... 7-43
5.10 Main Bearing Inside Diameter - Measure ............................................................................... 7-44
5.11 Thrust Plate - Inspect.............................................................................................................. 7-45
5.12 Crankcase Oil Hole - Inspect .................................................................................................. 7-45
5.13 Cylinder Liner Water Jacket - Inspect..................................................................................... 7-45
5.14 Crankcase Top Seal Face - Repair ........................................................................................ 7-46
7-2 99089-40100
1. Cylinder Head and Valve Mechanism - Inspect and Repair

1.1 Rocker Bushing Inside Diameter and Rocker Shaft Outside Diameter - Measure
Measure the inside diameter of the rocker bushing and the
outside diameter of the rocker shaft. If the measurement
exceeds the limit, replace the rocker bushing or rocker shaft
with a new one.
Measurement Nominal
Standard value Limit value
item value
Rocker bushing ø 48 mm 48.04 to 48.14 mm 48.24 mm
inside diameter [1.89 in.] [1.8913 to 1.8953 in.] [1.8992 in.]
Rocker shaft out- ø 48 mm 47.984 to 48.000 mm 47.95 mm
side diameter [1.89 in.] [1.8891 to 1.8898 in.] [1.8878 in.]
Rocker Bushing Inside Diameter and Rocker Shaft
Outside Diameter - Measure
1.2 Rocker Bushing - Replace

(1) Expand fit the rocker bushing to the rocker arm by
Rocker arm oil hole
aligning the rocker bushing oil hole (ø8 mm [0.32 in.]) (ø3.3 mm [0.13 in.])
to the hole (ø3.3 mm [0.130 in.]) of rocker arm.
(2) Check the alignment of the rocker arm and rocker bush-
ing oil holes.
(3) Measure the inside diameter of installed rocker bush-
ing. Ream the bushing if the value is out of the stan-
dard.
Bushing oil hole
(ø8 mm [0.31 in.])
Rocker Bushing - Replace
1.3 Nozzle Retainer Stud and Bridge Guide - Inspect and Replace
Inspect the Nozzle retainer stud and bridge guide. If heavy
Nozzle retainer stud bolt
wear or damage is found, replace part with a new one.
Tightening torque Apply engine oil
Note: Do not remove the nozzle retainer stud or bridge guide 98 N·m {10 kgf·m}
unless it is defective. [72 lbf·ft]
1.3.1 Nozzle Retainer Stud - Install

Apply Rocktite 271 or equivalent to the screw in thread of
the nozzle retainer stud bolt when replacing the stud.
Tighten to the specified torque to screw into the cylinder
head.
1.3.2 Bridge Guide - Install
Nozzle Retainer Stud Bolt and Bridge Guide - Remove
Chill the new bridge guide in liquid nitrogen to make the
temperature difference of 160°C [320°F] or more between
the guide and cylinder head to replace the bridge guide.
99089-40100
7-3
1.4 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure
Measure the outside diameter of valve stem and the inside
diameter of valve guide at the top and bottom ends and the
center of sliding surface in mutually right-angle directions
as shown, as the sliding surfaces tend to wear at the top and
bottom ends. If the measurement exceeds the limit, replace
the valve guide or the valve with a new one.
Note: Lap the valve and valve seat ring whenever a new
valve is installed.
Nominal Standard
Measurement item
value value
Limit value Valve Stem Outside Diameter - Measure
16.91 to
Inlet 16.93 mm 16.82 mm
valve [0.6657 to [0.6622 in.]
Valve stem out- ø17 mm 0.6665 in.]
side diameter [0.67 in.] 16.88 to
Exhaust 16.90 mm 16.74 mm
valve [0.6646 to [0.6591 in.]
0.6654 in.]
17.000 to
Valve guide inside diameter
ø17 mm 17.018 mm 17.14 mm
(same to the intake and
[0.67 in.] [0.6693 to [0.6748 in.]
exhaust)
0.6700 in.]
Valve Guide Inside Diameter - Measure

1.5 Valve Guide - Replace
Use the valve guide installer to pull out and press fit the
Valve guide installer
valve guide. P/N: 41091-01900
1.5.1 Valve Guide - Remove
Apply the valve guide installer to the bottom face of valve
guide. Tap it with a hammer to remove the guide.
Valve Guide - Remove

1.5.2 Valve Guide - Press Fit
Valve guide
Chill the valve guide in liquid nitrogen to make the temper- Installer
ature difference of 110°C [230°F] or more between the P/N: 41091-01900
guide and cylinder head. Expand fit the valve guide.
Note: Measure the valve guide inside diameter to confirm the
value is within the standard after installing the valve
guide. Ream the bushing if the value is out of the stan-
dard.
+0.018
Valve guide inside diameter ø17 0 mm
Valve-guide inside face roughness 0.8Ra
Valve Guide - Press Fit
7-4 99089-40100
1.6 Valve Face - Inspect

Inspect the valve face after the valve guide is inspected or
replaced. Lap the valve and valve seat ring whenever the Valve lapper
P/N: 30091-08800
valve is refaced or replaced.
Contact
checker
Valve Face - Inspect

1.6.1 Valve Margin - Inspect
Measure the valve margin. Replace the valve with a new
one if the limit is exceeded.
1.6.2 Seat Width - Inspect
Apply a thin coat of lead-free coloring paste on the valve
seat face, and tap the valve against valve seat ring with the
valve lapper to check the contact condition. If the contact is
not even, any defects are found, or if the value exceeds the
specified limit, reface or replace the valve or valve seat ring.
Note: Do not rotate the valve when pressing valve face coat-
ed with lead-free coloring paste against valve seat ring. Good Failure
Measurement item Standard value Limit value

Seat Width - Inspect
Inlet
30° -
Valve seat valve
angle Exhaust
30° -
valve Seat width
Inlet 1.0 to 1.9 mm 2.9 mm
Valve Valve valve [0.039 to 0.075 in.] [0.114 in.]
seat sinkage Exhaust 1.0 to 1.9 mm 2.9 mm
valve [0.039 to 0.075 in.] [0.114 in.]
Seat valve [0.150 to 0.165 in.] [0.205 in.] Valve Valve
width Exhaust 2.9 to 3.3 mm 4.3 mm seat Valve margine
valve [0.114 to 0.130 in.] [0.169 in.] angle sinkage
valve [0.209 to 0.224 in.] [0.185 in.] Contact Condition Between Valve Seat Ring and Valve
Valve margin
Exhaust 4.3 to 4.7 mm 3.7 mm
valve [0.169 to 0.185 in.] [0.146 in.]
99089-40100
7-5
1.7 Valve Face - Reface

When refacing valve face to reuse, use the valve refacer.
Note:(a) Grind the valve face with valve refacer adjusted to
the specified angle.
(b) The valve margin should be within the specified
limit. If the dimensions after refacing do not meet
the specified values, replace the valve with a new Grind the valve face
one. to fir to 30°.
Valve Face - Reface

1.8 Valve Seat Ring - Reface
If any damage or inclusions are found, grind the seat face.
(1) Reface the valve seat with valve seat cutter or valve
seat grinder. After refacing, insert sand paper of approx
400 grit between cutter and valve, and grind valve seat
lightly.
(2) Lap the valve and valve seat ring.
Note:(a) Keep the valve seat refacing depth to the minimum.
(b) Replace the valve seat ring with a new one if the
seat width is larger than the limit by wearing or
grinding.
Valve Seat Ring - Reface
(c) If the valve sinkage exceeds the specified limit after
refacing, replace the valve seat ring with a new one.
7-6 99089-40100
1.9 Valve Seat Ring - Replace
Select the valve seat ring with an appropriate interfer-

ence. Improper interference can result in dropping out
of a valve seat ring or a crack in cylinder head.
Be careful not to damage the machined surface of cylinder
head when removing the valve seat ring.
1.9.1 Valve Seat Ring - Remove by Welding
To remove the valve seat ring, weld a round-shape iron plate
to the ring as shown. Then, insert a shaft into the valve Weld
guide hole from the top of cylinder head, and punch out the Valve seat ring
valve seat ring. Shaft
Note: Be careful not to allow spatters to adhere to the ma-
Valve seat ring
chined surface of the cylinder head during welding.
Roun iron plate or others
Roun iron plate or others
Valve Seat Ring - Remove by Welding

1.9.2 Valve Seat Ring - Install
[0.81 0 ]
+0.0039
(1) Before installing the valve seat ring, measure the inside
+0.1
20.5 0
diameter of valve seat counterbore in cylinder head and
the outside diameter of valve seat ring to make sure that
the interference is within the range of standard value.
[0.43]
(2) Valve Seat - Install
11
Head inside diameter
Before inserting a new valve seat ring, measure the cyl- +0.065 +0.0026
ø85 +0.045 [3.35 +0.0018 ]
inder head bore diameter and valve seat ring outside Seat outside diameter
+0.225 +0.0089
diameter to make sure the interference meets the speci- ø85 +0.205 [3.35 +0.0081 ]
fied value. (Same to the intake and exhaust) Unit: mm [in.]

Valve Seat Ring Counterboring
Nominal
Measurement item Standard value
value
Clearance between valve-seat-
ring housing inside diameter and ø85 mm -0.140 to -0.180 mm [-
valve seat ring outside diameter [3.35 in.] 0.0055 to -0.0071 in.]
(same to the intake and exhaust)
Note: Minus (-) indicates the interference amount in diame-

ter.
(3) Chill the valve seat ring in liquid nitrogen to make the
Valve seat ring installer
temperature difference of 160°C [320°F] or more P/N: 41091-02100
between the ring and cylinder head. Expand fit the
valve seat ring.
Use the valve seat installer to install the valve seat ring.
Valve seat ring
Valve Seat Ring - Install
99089-40100
7-7
1.10 Valve and Valve Seat Ring - Lap

Lap the valve against the valve seat ring whenever the valve
seat ring is refaced or the valve is replaced.
(1) Apply a thin coat of lapping compound evenly on valve
seat face.
Note:(a) Do not allow the compound to adhere to the valve
stem.
(b) The compound spreads more evenly when it is Compound
mixed with a small amount of engine oil.
(c) Use a medium-grain compound (125 to 150 mesh)
for initial lapping, then use the fine-grain com-
Compound - Apply
pound (200 mesh) for finishing.
(2) Use a valve lapper for lapping.
Valve lapper
Tap the valve against the valve seat while rotating the P/N: 30091-08800
valve little by little.
(3) Wash off the compound using diesel fuel.
(4) Apply engine oil on mating surfaces, and lap for finish-
ing.
(5) Apply a thin coat of lead-free coloring paste on the
valve face, and tap the valve face against the valve seat
using a valve lapper to check the contact condition.
Valve and Valve Seat Ring - Lap

1.11 Bridge, Valve Stem Upper Portion, Bridge Guide and Valve Rotator - Inspect
(1) Check the valve stem upper portion, then replace the
valve if the wear is excessive.
(2) Check the valve guide. Replace the guide with a new
one if it is excessively worn.
(3) Check the valve rotator for rotation. If any defect is
found, replace the valve rotator with a new one.
1.12 Squareness and Free Length of Valve Spring - Measure
Measure the squareness and the free length of valve spring.
If the free length or squareness exceeds the limit, replace the
valve spring with a new one.
Spring perpendicularity (gap)
Limit
value
107 mm 102 mm Free length
Free length
[4.21 in.] [4.02 in.]
ǰ
At the
ٌ whole
Squareness θ=1°or less length
Lf
B=2.8 mm
[0.110 in.] Squareness and Free Length of Spring - Measure
100 mm [3.94 in.] / 525 to 593 N
Set length / load {53.5 to 60.5 kgf} -
[118.03 to 133.31 lbf]
7-8 99089-40100
1.13 Clearance Between Tappet Guide Set Screw Hole and Set Screw - Check
Install the tappet guide and tappet guide set screw in the
Tappet guide
crank case. Move the tappet by hand and measure the clear-
Tappet
ance between the tappet guide set screw hole and the set
screw. Tappet guide
set screw
Replace the tappet guide and tappet guide set screw with
new ones if the vertical moving stroke exceeds the limit. Spring washer
Limit Tappet guide

Measurement item Standard value set screw hole
value
Clearance between tappet-guide set 0.0 to 0.3 mm 1.2 mm
screw hole and set screw [0.000 to 0.012 in.] [0.047 in.]
Part Names of Tappet and Tappet Guide
Clearance Between Tappet Guide Set Screw Hole and

Set Screw - Check
99089-40100
7-9
1.14 Tappet and Tappet Guide - Measure

Measure the tappet guide inside diameter, tappet outside
diameter, tappet roller inside/outside diameters, tappet roller Measuring
direction
bushing inside/outside diameters and tappet roller shaft out-
Measuring
side diameter. Replace the part with a new one if it exceeds position
the limit.
Measuring
direction
Tappet guide
Tappet
Tappet Guide Inside Diameter and Tappet Outside
Diameter - Measure
Measurement location Nominal value Standard value Limit value Remark

ø58 mm 58.000 to 58.030 mm
Tappet guide inside diameter -
[2.28 in.] [2.2835 to 2.2846 in.]
57.921 to 57.940 mm
-
ø58 [2.2803 to 2.2811 in.]
Tappet outside diameter
[2.28] 57.894 to 57.940 mm
-
[2.2793 to 2.2811 in.]
0.06 to 0.109 mm 0.250 mm
-
[0.0024 to 0.0043 in.] [0.0098 in.]
The clearance above
0.06 to 0.136 mm 0.250 mm
[0.0024 to 0.0054 in.] [0.0098 in.]
ø36 mm 36.025 to 36.066 mm
Tappet roller inside diameter -
[1.42 in.] [1.4183 to 1.4199 in.]
ø36 mm 35.870 to 35.890 mm
Tapper roller bushing outside diameter -
[1.42 in.] [1.4122 to 1.4130 in.]
0.135 to 0.196 mm 0.250 mm
The clearance above -
[0.0053 to 0.0077 in.] [0.0098 in.]
ø22 mm 22.150 to 22.190 mm
Tappet roller bushing inside diameter -
[0.87 in.] [0.8720 to 0.8736 in.]
ø22 mm 22.002 to 22.011 mm
Tapper roller shaft outside diameter -
[0.87 in.] [0.8662 to 0.8666 in.]
0.139 to 0.188 mm 0.250 mm
[0.0055 to 0.0074 in.] [0.0098 in.]
ø51 mm 50.9 to 51.1 mm 50.7 mm
[2.01 in.] [2.004 to 2.012 in.] [1.996 in.]
Tapper roller outside diameter
ø50 mm 49.9 to 50.1 mm 49.7 mm
[1.97 in.] [1.965 to 1.972 in.] [1.957 in.]
1.15 Pushrod Runout - Measure

Measure the runout of pushrod in the total indicator reading
(TIR). If the runout exceeds the standard, replace the push-
rod with a new one.
Measurement Push rod

Standard value Remark
item
Pushrod runout 0.50 mm [0.0197 in.] or less TIR
1/2L 1/2L
Pushrod Runout - Measure
7-10 99089-40100
1.16 Cylinder Head Gas Sealing Face - Reface

Polish the cylinder head gas sealing face with the cylinder
head polisher on overhauling.
1.16.1 Preparation of polishing
(1) Prepare sandpaper (commercial item) of grit 120, 240 Width of
double-faced tape
and 800 and double-faced tape (commercial item). Cut 15 to 25 mm
the sandpaper to the same width (15 to 25 mm [0.59 to [0.59 to 0.98 in.]
0.98 in.]) as that of the double-faced tape. Stick the Cut.
double-faced tape to the back side of sandpaper.

(2) Cut the sandpaper with double-faced tape to 30 to 40
mm in length. Cut one side of sandpaper to fit to the
Sand paper
head polisher periphery. Stick 12 pieces of sandpaper to
the cylinder head polisher aligning its side shape to the
Sandpaper and Double-Faced Tape - Cut
polisher periphery.
Note: Pay attention to keep the cylinder head polisher sur- Width of
double-faced tape
face to be free from the scar and hitting mark during 15 to 25 mm
the handling and storing. [0.591 to 0.984 in.] 30 to 40 mm
[1.118 to 1.575 in.]
The gas sealing face may be defective if the polishing
Attach sand paper Cut along the
is done with a scar or hit mark on the polishing surface. to be flush with outside diameter.
the outside diameter.
Cylinder head
polisher
Sandpaper - Stick
1.16.2 Procedure to polish the cylinder head gas seal-
Place the cylinder head polisher squarely to the cylinder head
ing surface. gas sealing face, and press and rotate the polisher.
Reverse the turning direction once in every ten turnes.
Hold firmly the bars of cylinder head polisher with both
Press squarely to the gas
hands. Rotate the polisher by pressing it squarely. Rotate the sealing face,
and rotate slowly.
polisher slowly to avoid local polishing and waggle.
Reverse the rotating direction at approx every ten turns. Sand paper
Note:(a) Clean the sandpaper with a wire brush when it is

clogged. Replace the sandpaper timely when it is Cylinder
worn. head polisher
P/N: 41091-06800
(b) Do not apply oil. Polish in a dry condition. Do not
use a lapping compound (for valve seat) as it dam- Procedure to Polish the Cylinder Head Gas Sealing
Surface.
age the cylinder head polisher.
(c) Grind the cylinder head gas sealing face with 240
grid sand paper when the asperity of the sealing
face is shallow.
(d) Polish the sealing surface with 120 grid sand paper
when the asperity is deep. Then use 240 grid sand
paper to grind the surface again.
99089-40100
7-11
1.16.3 Cylinder Head Gas Sealing Face - Check

Contact check gauge
P/N: 41091-06900
Check the contact

The engine may cause a gas leak during the engine
with the gauge.
operation if the polishing is defective. Apply a thin coat
of lead-free contact checker.
(1) Apply a thin coat of contact checking compound (lead
free marking blue or the like) to the contact gage and
check the face contact of gas sealing surface.
Note: Repeat the polishing if the contact is not even on the Cylinder-head gas sealing face
whole sealing face.
Cylinder Head Gas Sealing Face - Check
(2) Use 800 grid sandpaper for finish-polishing after the
even contact on the whole sealing face is verified.
(3) Check the gas sealing face again for the even whole Before polishing.
face contact with the contact gauge. Defective contact position
Polishing
first stage. Contact face to the gauge
with a lead-free contact checker
Polishing
completed. Polish the upper sealing face to make a whole face
contact to the gauge with lead-free contact checker.
Polish the gas sealing surface until the contact
to the gauge becomes to the whole sealing surface
Cylinder Head Gas Sealing Face - Judge
7-12 99089-40100
2. Rear Mechanism - Inspect and Repair

2.1 Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure
Measure the idler bushing inside diameter and the idler shaft
outside diameter.
Replace the idler gear and idler bushing as a set if the value
exceeds the limit.
Measure- Nominal
ment item value
Idler bushing ø85 mm 85.000 to 85.022 mm
-
inside diameter [3.35 in.] [3.3465 to 3.3473 in.]
Idler shaft ø85 mm 84.942 to 84.964 mm
-
diameter [3.35 in.] [3.3442 to 3.3450 in.]
The clearance 0.036 to 0.080 mm 0.20 mm Idler Bushing Inside Diameter and Idler Shaft Outside
- Diameter - Measure
above [0.0014 to 0.0031 in.] [0.0079 in.]
2.2 Cam Lift -Measure

Measure the major diameter and minor diameter of inlet and
exhaust cam lobes with a micrometer. Replace the camshaft
if its cam lift exceeds the limit.
Replace the fuel injection pump cam shaft if the cam shows Inlet and exhaust cam
Micrometer
significant wear.
A
Nominal Standard
Measurement item Limit value
value value B
16.980 to
Cam lift Inlet and 17 mm 17.020 mm 16.930 mm
(A - B) Exhaust [0.67 in.] [0.6685 to [0.6665 in.]
0.6701 in.] Cam Lift -Measure
2.3 Camshaft Runout - Measure

Measure the runout of camshaft in TIR. If the value exceeds
the limit, correct the camshaft using a press, or replace the
camshaft with a new one.
Note: With a dial gauge set on the camshaft, rotate the cam-
shaft one turn and read the gauge indication.
Measurement
Standard value Limit value Remark 1/2 1/2
item
0.10 mm [0.0039 in.] 0.16 mm
Camshaft runout TIR
or less [0.0063 in.]
Camshaft Runout - Measure
99089-40100
7-13
2.4 Camshaft Journal Outside Diameter - Measure

Measure the diameter of each camshaft journal in two direc-
tions at right angles to each other. If the value exceeds the
limit, replace the camshaft with a new one.
Micrometer
Measurement Nominal Standard
Limit value
item value value
127.890 to Measuring direction
Camshaft journal ø128 mm 127.915 mm (0.400 mm
outside diameter [5.04 in.] [5.0350 to [0.0157 in.])
5.0360 in.]
Note: The limit value shows the clearance to the camshaft

bushing inside diameter. Camshaft Journal Outside Diameter - Measure
2.5 Camshaft Bushing - Inspect and Replace
2.5.1 Camshaft Bushing - Inspect
(1) Check inside surface of each bushing for damage, cor-
rosion, flaking and other abnormalities. If any defect is
found, replace the camshaft bushing with a new one.
(2) Measure the inside diameter of the camshaft bushing
placing the bushing in the crankcase. If the value
exceeds the limit, replace the camshaft.
Note: Be careful not to damage the inner surface of camshaft
bushing when measuring the inside diameter.
Measurement Nominal
item value
128.007 to
Camshaft bushing ø128 mm 128.073 mm (0.400 mm Measuring direction
inside diameter [5.04 in.] [5.0396 to [0.0157 in.])
5.0422 in.] Camshaft Bushing Inside Diameter - Measure
Note: The limit value shows the clearance to the camshaft
journal.
2.5.2 Camshaft Bushing - Remove
Pull out the camshaft bushing with a hydraulic jack. Camshaft bushing Hydraulic jack
Note:(a) A set screw is provided on the rearmost camshaft
bushing. Remove the set screw, then push out the
bearing with the jack.
(b) Place a hydraulic jack in the cam chamber through
the inspection window, and place a plate or the like
which can support the hydraulic jack to prevent the
crankcase from damaging with the hydraulic jack Iron plate Iron plate Plate
bottom end.
Camshaft Bushing - Remove
(c) Insert the iron plate of ø140 mm [5.512 in.] in align-
ing with the bushing with the jack top end.
(d) Apply the hydraulic oil pressure slowly and remove
the camshaft bushing.
Note: Pay attention not to damage the crankcase when re-
moving the camshaft bushing.
7-14 99089-40100
2.5.3 Camshaft Bushing - Install

Align the crankcase
and camshaft oil holes
Do not apply heat to the crankcase with burner or the
like when installing the camshaft bushing. Gasket
(1) Check the camshaft bushing housing in the crankcase Set screw
for a detrimental damage or others, and clean well the
face.
(2) Chill the camshaft bushing in liquid nitrogen or the
like. Raise the temperature of crankcase to make the
temperature difference to be 160°C [320°F] or more, Rearmost Camshaft Bushing - Position (1)
and expand fit the bushing in the crankcase. Rear most canshaft
Place the wide camshaft bushing in the rearmost hous- bushing
Gasket Oil hole
ing. Align the bushing oil hole to the crankcase oil hole
and install. Set screw
Position the bushing with a set screw after installing.
From main gallery

Crankcase
Rearmost Camshaft Bushing - Position (2)
99089-40100
7-15
3. Front Mechanism - Inspect and Repair

3.1 Damper - Inspect
(1) Check the damper body for contact mark, discoloration,
Contact mark, discoloration,
hit mark, and cover bulge with a straight scale. Sample dent, deformation
the silicone oil and inspect its property if the damper
shows some abnormality.
(2) Check the thermo-ravel struck on the damper side face
for the damper maximum temperature. If it shows 90°C
or higher, sample the silicone oil and inspect its prop-
erty.
(3) Check the damper for silicone oil leak from the fitting Silicone oil leak
face of cover and body or front face plug, and oil adhe-
Damper - Inspect
sion on dumper cover inner face. replace the damper if
it is defective. Welding
(4) Sample the silicone oil at every 12000 operating hours (or bolt fixing)
Silicone oil leak
and check the silicone oil properties, even when discol-
oration, deformation or leak is not observed.
Plug
Silicone oil inclusion case
Part Names of Damper

3.2 Sampling of silicone oil from the damper
The decrease of kinetic viscosity of silicone oil sealed in the
Thermo lavel 㸺5E-75㸼 Thermo lavel 㸺5E-100㸼
damper can result in a serious accident of the engine. Sam-
ple the silicone oil at every 12000 operating hours and
75 80 85 90 95 100 105 110 115 120
Thermo lavel
check the properties.
(Recommended regular replacement interval of the damper:
Every 48000 hours)
Measurement item Part number

Dampers which are required to check the sili-
41222-00801 Double damper spec
cone oil properties.
Thermo-label - Inspect
7-16 99089-40100
Upper
The silicone oil may spout from the damper if the plug
is loosened immediately after the engine stopping, as
Punch
the temperature in the damper is raised.
(1) Cool down the damper temperature to 40 to 50°C [104
Plug
to 122°F] after stopping the engine.
(2) Remove the damper cover.
(3) Turn the damper to bring the two plugs on the front face
to a horizontal position. Lower
(4) Prepare the sampling kit, and remove the cap of only Plug to Extract the Silicone Oil
one side on the sampling plug.
(5) Loosen the punched staking of one plug of the two, and
Cap
remove the plug from the damper with the damper plug
wrench. Plug
Note: Closely fit the damper plug wrench to the plug and Sampling kit
P/N: 41091-09300
turn.
Seal
washer
Sampling Plug
Damper plug
dedicated wrench
Torque wrench
P/N: 41091-09500
Align the protrusion

to the plug notch
Damper Plug Wrench
Damper plug
dedicated socket Torque wrench
P/N: 41A91-08700
Damper Plug Socket
99089-40100
7-17
(6) Install the sampling plug quickly not to let the silicone
oil flowing out from the damper.
Sampling plug
(7) Remove the other side cap of the sampling plug. Then 20 N·m
install the cap quickly before the silicone oil flows out {2 kgf·m}
[14.75 lbf·ft]
from the plug.
Note:(a) The flowing out rate differs depending on the sili-
cone oil viscosity. When a faster flowing out is re-
quired, turn the damper to bring the sampling plug
at the bottom position and remove the staked plug
on the damper.
Sampling Plug - Install
(b) If the silicone oil does not flows out, collect the sil-
icone oil around the plug hole with a flat tip driver
or the like. Sampling plug
(8) Remove the sampling plug and install the cap to the
open end.
Note: Press the cap into the place until a click is heard.
(9) Remove the silicone oil sticking to the plug fitting face
of damper. Replace the sealing washer to the new one
attached to the sampling kit.
Cap
Install the removed plug to the hole. Tighten it by hand
as much as possible. Then tighten the plug to the speci- Silicone Oil - Extract
fied torque with the damper plug wrench.
(10)Stake the plug by punching on the damper face at the
plug periphery groove positions.
7-18 99089-40100
3.3 Silicone Oil Property Check

3.3.1 Silicone oil kinetic viscosity check
The kinetic viscosity check is done by measuring the oil
level descending rate.
(1) Adjust the silicone oil temperature to 25 ± 10°C [77 ±
18°F] for the checking of kinetic viscosity.
(2) Hold the sampling plug in a vertical position, and let air
bubbles out from inside the silicone oil.
(3) The silicone oil starts to drop when the caps on both
ends are removed. Measure the time to allow the sili-
cone oil to descend by 30 mm [1.18 in.]. If the time is
Preparation of Silicone Oil Level Descending Time
blow the limit, replace the damper with a new one.
Measurement

Time for silicone oil level
to descend by 30 mm 14 min. and 20 sec. 7 min. and 10 sec.
30 mm
[1.18 in.]
[1.1811 in.]
Silicone oil kinetic viscos-
5.0×10 5 2.5×10 5
ity mm2/s
3.3.2 Checking silicone oil color and inclusion of for-

eign materials
Replace the damper with a new one if the silicone oil is col-
ored or metallic powder inclusion is found.
Silicone Oil Level Descending Time Measurement
Measurement item Standard Limit 30

Colorless and Colored or metallic pow-
Measured time (min.)
Silicone oil color 25

clear der inclusion is found.
20
15
14 min. and
Standard value
20 sec.
10
7 min. and
10 sec. 5 Limit
the damper
with a new one.
0 2.5
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
Kinetic viscosity (25 Υ [77 rF] 10ੈ/s)
Silicone Oil Viscosity to Measured Time
3.4 Damper Temperature Control
To ensure the proper function of the damper, the heat gener-
ated in the damper must be released from the surface to pre-
vent the damper from over-heating.
We check the damper temperature not to raised excessively
before shipping. However the damper temperature may var-
ies with the environmental condition. Obey the instruction
below, and pay attention to the ventilation and facility
around the damper.
Operate the engine at the rated power for approx. one hour.
Check the damper periphery temperature to be 90°C
[194°F] or blow.
Note: We recommend thermo-labels for the controlling of
damper temperature.
99089-40100
7-19
3.5 Visual Inspection of Accessory Drive

Visually inspect the accessory drive consisting parts below. replace the part if detrimental scuffing, poor thooth contact, local
wear or any other abnormality is found.
Replace the bearings at every 24000 hours, irrespective of their condition.
Inspection items Inspection item

Front gear case Oil pump idler shaft hole damage, wear, crack, damage, dowel hole defect
Idler gear support Bearing housing scuffing, local wear, defective dowel hole defect
Idler gear Poor tooth contact, inside hole scuffing
Idler shaft Damage, wear, scuffing
Oil pump idler gear Poor tooth contact, inside hole scuffing
Oil pump idler shaft Damage, wear, scuffing
Oil pump idler shaft retainer Damage, wear, scuffing
Bearing Poor rotation, damage
Oil pump idler shaft

damage, wear, scuffing
Idler gear
Oil pump idler gear poor tooth contact, inside hole scuffing
poor tooth contact, inside hole scuffing
Front gear case

pump idle shaft hole damage,
wear, crack, damage, dowel hole defect
Idler shaft
Oil pump idler shaft

Idler gear support
bearing hole scuffing,
local wear, dowel pin hole defect
Visual Inspection of Accessory Drive
7-20 99089-40100
3.6 Dimensional Measurement of Accessory Drive

Measure the accessory drive consisting parts. Replace the
part with a new one if the measurement exceeds the limit.
3.6.1 Idler Gear Inside Diameter and Idler Gear Bear-
ing Outside Diameter -measure.
Nominal
value
Inside diameter of ø90 mm 89.955 to 89.990 mm
-
idler gear [3.54 in.] [3.5415 to 3.5429 in.]
Idler gear bearing ø90 mm 89.985 to 90.000 mm
-
outside diameter [3.54 in.] [3.5427 to 3.5433 in.]
Idler Gear Inside Diameter and Idler Gear Bearing
-0.045 to 0.005 mm -0.05 mm
Interference above - Outside Diameter - Measure
[-0.0018 to 0.0002 in.] [-0.0020 in.]
Note: The - (minus) of interference shows the clearance
3.6.2 Idler Shaft Outside Diameter and Idle Gear

Bearing Inside Diameter - Measure
Nominal
value
ø40 mm 39.984 to 40.000 mm
[ø1.57 in.] [1.5742 to 1.5748 in.]
Idler gear bearing ø40 mm 39.998 to 40.000 mm
-
inside diameter [ø1.57 in.] [1.5747 to 1.5748 in.]
-0.016 to 0.012 mm -0.05 mm
Interference above -
[-0.0006 to 0.0005 in.] [-0.0020 in.]
Note: The - (minus) of interference shows the clearance Idler Shaft Outside Diameter and Idle Gear Bearing
Inside Diameter - Measure
3.6.3 Oil Pump Idler Gear Inside Diameter and Oil

Pump Idler Gear Bearing Outside Diameter -
measure
Nominal
value
Oil pump idler gear ø80 mm 79.961 to 79.991 mm
-
Oil pump idler gear
ø80 mm 79.987 to 80.000 mm
bearing outside -
[3.15 in.] [3.1491 to 3.1496 in.]
diameter
-0.004 to 0.039 mm -0.05 mm Oil Pump Idler Gear Inside Diameter and
[-0.0002 to 0.0015 in.] [-0.0020 in.]
Oil Pump Idler Gear Bearing Outside Diameter -
Note: The - (minus) of interference shows the clearance Measure
99089-40100
7-21
3.6.4 Oil Pump Idler Shaft Outside Diameter and Oil

Pump Idler Gear Bearing Inside Diameter -
Measure
Nominal
value
Oil pump idler shaft ø35 mm 34.984 to 35.000 mm
-
diameter [1.38 in.] [1.3773 to 1.3780 in.]
Oil pump idler gear
ø35 mm 34.988 to 35.000 mm
bearing inside diam- -
[1.38 in.] [1.3775 to 1.3780 in.]
eter
-0.016 to 0.012 mm [- -0.05 mm Oil Pump Idler Shaft Outside Diameter and
0.0006 to 0.0005 in.] [-0.0020 in.]
Oil Pump Idler Gear Bearing Inside Diameter -
Note: The - (minus) of interference shows the clearance. Measure
7-22 99089-40100

Measure the gear backlash with a dial gauge applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or mea-
sure the clearance between gears by inserting a feeler gauge between the engaging gear teeth.
Measure the backlash of crank gear and idler gear while the front gear case is installed on the crankcase.
Remove the front gear case from the crankcase and keep the water pump and oil pump installed, and measure the backlash
between idler gear and water pump gear, idler gear and idler gear, water pump gear and oil pump idler gear, and oil pump idler
gear and oil pump gear.

Backlash between crank gear and idler gear 0.10 to 0.28 mm
Backlash between idler gear and high-temperature system water pump gear [0.0039 to 0.0110 in.]
Backlash between idler gear and low-temperature water pump gear 0.5 mm
Backlash between idler gear and idler gear [0.020 in.]
0.10 to 0.22 mm
Backlash between high-temperature system water pump gear and oil pump idler gear [0.0039 to 0.0087 in.]
Backlash between oil-pump idler gear and oil pump gear
A
Crank gear
Damper
Idler gear
Idler gear
Backlash
0.10 to 0.28
[0.004 to 0.011]
Backlash
0.10 to 0.22
[0.004 to 0.009]
B
Water pump gear Backlash B
Backlash
0.10 to 0.28 0.10 to 0.22
[0.004 to 0.011] [0.004 to 0.009]
Backlash
0.10 to 0.22 Water pump
High-temperature [0.004 to 0.009]
[0.004 to 0.009] Water pump gear
circuit
water pump Low-temperature system
water pump
Oil pump idler gear

Oil pump
Oil pump gear
B-B A
Oil pump
A-A
99089-40100
7-23
4. Cylinder Liner, Piston and Connecting Rod - Inspect and Repair

4.1 Cylinder Liner Gas Sealing Face - Reface
Polish the cylinder liner gas sealing surface if the cylinder
liner is continuously used after overhauling. Polish the cyl-
inder liner gas sealing face with the cylinder liner polisher.
4.1.1 Preparation of Polishing

double-faced tape
the sandpaper to the same width (15 to 25 mm [0.591 [0.59 to 0.98 in.]
to0.7874 in.]) as that of the double-faced tape. Stick the Cut.

mm in length. Cut one side of sandpaper to fit to the
Sand paper
liner polisher inner periphery.
Stick 12 pieces of sandpaper to the cylinder liner pol-
isher aligning its side shape to the polisher inner periph-
ery. Width of
double-faced tape
Note: Pay attention to keep the cylinder liner polisher surface 15 to 25 mm
to be free from the scar and hitting mark during the [0.591 to 0.984 in.] 30 to 40 mm
[1.118 to 1.575 in.]
handling and storing.
The gas sealing face may be defective if the polishing to be flush with inside diameter.
is done with a scar or hit mark on the polishing surface. the inside diameter.
Cylinder liner
polisher
P/N: 41091-06600
Sandpaper - Stick
7-24 99089-40100
4.1.2 Procedure to Polish the Cylinder Liner Gas Place the crankcase polisher squarely to the crankcase
Sealing Surface upper sealing face, then press and slowly rotate the polisher.
Reverse the rotational direction once in every ten turnes.
Hold firmly the bars of cylinder liner polisher with both Press squarely to the upper sealing face, and rotate slowly.
hands. Rotate the polisher by pressing it squarely. Rotate the Reverse the turning direction once in every ten turns.
polisher slowly to avoid local polishing and waggle. Cylinder liner

polisher
Reverse the rotating direction at approx every ten turns.
clogged. Replace the sandpaper timely when it is
worn. Sand paper

Procedure to Polish the Cylinder Liner Gas Sealing
use a lapping compound (for valve seat) as it dam-
Surface
age the cylinder liner polisher.
(c) Grind the cylinder liner gas sealing face with 240
grid sand paper when the asperity of the sealing
face is shallow.
4.1.3 Cylinder Liner Gas Sealing Face - Check

Contact check gauge
P/N: 41091-06900
The engine may cause a gas leak during the engine Apply a thin coat
of lead-free contact checker
operation if the polishing is defective.
(1) Apply a thin coat of contact checking compound (lead Check the contact
with the gauge
check the face contact of gas sealing surface. Cylinder liner
gas seal face
Note: Repeat the polishing if the contact is not even on the
whole sealing face.
(2) Use 800 grid sandpaper for finish-polishing after the Cylinder Liner Gas Sealing Face - Check
even contact on the whole sealing face is verified.
(3) Check the gas sealing face again for the even whole Before polishing.
face contact with the contact gauge. Defective contact position
Polishing
first stage. Contact face check
Polishing
completed. Polish the upper sealing face to make
a whole face contact to the gauge
with lead-free contact checker
Cylinder Liner Gas Sealing Face - Judge
99089-40100
7-25
4.2 Clearance Between Cylinder Liner and Cylinder Head - Check

The cylinder liner and cylinder head may contact after the
gas sealing face polishing. Check the clearance between the
gap Cylinder head
cylinder liner and cylinder head after polishing the gas seal-
ing face. A
B
(1) Measure the dimensions A, B and t, and calculate the t
clearance between the cylinder liner and cylinder head.
Cylinder liner
Note: A + t - B = Clearance between the cylinder liner and
cylinder head
Sealing ring

Clearance Between Cylinder Liner and Cylinder Head
Clearance between cylinder head and cylinder 0.1 mm
liner [0.004 in.] or more
- Check
(2) Replace the seal ring from 41010-00401 (t1.8±0.05) to

41010-01501(t2.0±0.05) and check the clearance
between the cylinder liner and cylinder head, the clear-
ance is blow the standard.
Note: The seal ring 41010-01501 shows "t2.0" on its face for
identification.
(3) If the clearance is still below the standard after replac-
ing the seal ring, replace the cylinder liner or cylinder
head. Use the seal ring of 41010-00401 and check the
clearance to be within the standard.
Then, if the clearance is below the standard, use the seal
ring of 41010-01501 and check the clearance.
4.3 Piston - Check

The weight difference in one engine must be within the per-
Piston crown Combustion face
missible range.
O-ring
Measurement item
Tolerance of piston weight
Standard value
140 g [4.938 oz.] in one engine
Piston crown 㹹
Ring groove
fixing bolt
(1) Remove the carbon and other deposits around the piton Collar Collar bearing
face R portion
periphery, in the piston ring groove and on the combus-
Piston body
tion surface with a scraper or the like.
Piston pin bore
(2) Check the piston periphery, combustion surface, piston Piston pin boss
ring groove and piton pin bore inside face. Replace the Name of the Piston Each Position
piston if it is defective.
7-26 99089-40100
4.4 Piston - Disassemble
Do not insert a metal bar or the like through the piston

pin bore, or fix the piston by clinching its periphery
Wooden bar
with a vise. It will deform the piston.
(1) Place the piston positioning its crown downward, insert

a wooden bar or the like into the piston bore to prevent
the piston from rotating.
Piston
(2) Remove the piston crown fixing bolt and remove the
collar.
Insert a Wooden Bar Into the Piston Pin Bore.
(3) Insert a bar through the center oil hole of piston body
and tap the bar to separate the piston crown from the
piston body.
(4) Clean the deposits on the back face of piston crown and Push rod
upper face of piston body with brush, waste cloth and

cleaning liquid. Check defects such as detrimental
Piston body
wear, crack and fretting. Replace the part if it is defec-
central oil hole
tive.
(5) Check the piston body bolt holes with liquid penetrant
inspection. Check the collar spherical face of piston
body and collar bearing face, and piton crown fixing Piston Body and Piston Crown - Separate
bolt thread and bearing face. Replace it with a new one
if it is defective.
Piston crown fixing bolt
(6) Apply grease to the new O-ring and install on the piton 59 N·m {6 kgf·m} [43.52 lbf·ft]
body. Apply Moly LG Grease No.2
(7) Fit the piston crown to the piston body and apply a
small amount of Moly LG Grease No.2 or equivalent to
the thread of piston crown fixing bolt.
(8) To ensure a snug contact of collar seating face, tighten
the four piston crown fixing bolts and loosen them
twice.
(9) Tighten the piston crown fixing bolt to the specified Tightening Torque of Piston Crown Fixing Bolt
torque.
99089-40100
7-27
4.5 Piston Ring Groove Clearance - Measure
Measure the clearance at piton whole circumference. Feeler gauge
(1) Clean the deposits of carbon or others from each ring

groove. Check the piston and replace the piston with a
new one if it is worn or damaged.
(2) Install a new piston ring in the piston ring groove, and
measure the clearance with feeler gauges.
Straight edge
Press in the ring to be flush with the land in the case of
No1 to No.3 rings.
Clearance Between Piston Ring Groove - Measure
If the limit is exceeded, replace it with a new one.

General use 0.18 to 0.25 mm 0.30 mm
No. 1 Marine [0.0071 to 0.0098 in.] [0.0118 in.]
Clearance ring Emergency 0.13 to 0.20 mm 0.30 mm
between use [0.0051 to 0.0079 in.] [0.0118 in.]
piston ring
0.09 to 0.16 mm 0.30 mm
groove and No. 2 ring
[0.0035 to 0.0063 in.] [0.0118 in.]
piston ring
(Inserting 0.06 to 0.13 mm 0.30 mm
No. 3 ring
new ring) [0.0024 to 0.0051 in.] [0.0118 in.]
0.04 to 0.11 mm 0.30 mm
Oil ring
[0.0016 to 0.0043 in.] [0.0118 in.]
4.6 Clearance Between Piston Pin Bore and Piston Pin Diameter
Measure the piston bore with a cylinder gauge, and the pis-
ton outside diameter with a micrometer. If the value exceeds
the limit, replace the piston or piston pin with a new one.
Measurement Nominal
Standard value Limit value X
item value
Max reference Y
Piston pin hole ø100 mm 100.002 to 100.012 mm
(100.0435 mm
[3.9387 in.])
Min reference
Front Rear
Piston pin out- 99.985 to 100.000 mm
- (99.9535 mm
side diameter [3.9364 to 3.9370 in.]
[3.9352 in.])
Piston Pin Hole Inside Diameter - Measure
Clearance
between piston
(0.002 to 0.027 mm (0.09 mm
pin bore and -
[0.0001 to 0.0011 in.]) [0.0035 in.])
piston pin diam-
eter
Measuring
direction
Measuring
position
Piston Pin Outside Diameter - Measure
7-28 99089-40100
4.7 Standard for Piston Ring Replacement
Replace the piston rings with new ones at every peri-

odical overhaul even if they are considered to be reus-
able. Sustained use of old piston rings can lead to
abnormal engine operation such as increased blow-by
combustion gas.
Piston rings should be replaced with new ones at every

overhaul unless otherwise specified.
However, at an engine disassembling for some reason
before the next periodical overhaul, the piston ring replace-
ment is not required, provided that no abnormalities are
found when making the following inspections.
4.7.1 Piston Ring - Inspect Visually
Check the sliding surface for seizure, sticking, abnormal
wear and plate scoring due to carbon inclusion or others. If
any such traces are found, replace the piston rings with new
ones.
4.7.2 Piston Ring End Gap -Measure
Place the piston rings in a gauge or a new cylinder liner, and
measure the gap of each ring with feeler gauges.
If the value exceeds the limit, replace them as a set with a Piston ring
Feeler gauge
new one.
Gauge inside diameter

240 ± 0 mm [9.45 ± 0.00 in.]
Measurement item Standard value Limit value End gap

General use 0.08 to 1.10 mm 1.6 mm Piston Ring End Gap - Measuring
No. 1 Marine [0.0031 to 0.0433 in.] [0.063 in.]
ring Emergency 0.90 to 1.20 mm 1.6 mm
use [0.0354 to 0.0472 in.] [0.063 in.]
Piston ring 0.65 to 0.95 mm 1.4 mm
No. 2 ring
end gap [0.0256 to 0.0374 in.] [0.055 in.]
0.65 to 0.95 mm 1.4 mm
No. 3 ring
[0.0256 to 0.0374 in.] [0.055 in.]
0.75 to 1.05 mm 1.4 mm
Oil ring
[0.0295 to 0.0413 in.] [0.055 in.]
99089-40100
7-29
4.8 Piston Pin - Check
If a different weight piston pin is assembled in the

engine, an abnormal vibration will be generated and
the engine is damaged. Be sure to assemble the
same type piton pin in each cylinder.
Clean the piston pin after disassembling. Apply an in

inspection such as the magnaflux inspection or others to
Plug type
check the detrimental crack. Replace with a new one if it is (Approx. 11kg [24 lb.])
defective. When a sealing-cap-type piston pin is repalced,
Piton pin shape
do not replace the piston pin only. Replace all of the piston
pins in the engine to the plug type pins.
4.9 Connecting Rod - Inspect

Inspect the connecting rod at the E rank (every 12000 hours)
overhaul in the case of land continuous use spec.
(1) Conduct the magnetic particle inspection of connecting
rod serration. Check the crack at the inside and bottom
of connecting-rod tightening-thread hole.
(2) Replace the connecting rod to the 11 mm-pitch-serra-
tion connecting rod in all cylinders, if it is defective.
7-30 99089-40100
4.10 Connecting Rod Big End Thread Hole - Roll

Use the cut-thread tap, roll-form tap and thread gauge to roll
form the thread hole at the big end of connecting rod with-
out thread-hole roll forming.
Also at the thread hole roll forming, check the crack at the
inside and bottom of thread hole.
4.10.1 Thread Hole Forming - Inspect
Check the bottom of thread hole for flaw with liquid pene-
trant inspection as a preparation of the thread hole roll form-
ing.
After dyeing the thread hole, check the flaw with a bore
scope.
Note: The penetrant inspection must be conducted only at the
two thread holes on stamped side.
4.10.2 Processing with Cut Thread Tap and Roll Form-
ing Tap
Use a tap wrench (on the market, 460 mm [18.11 in.] long)
and process the thread hole by hand power (approx. 100
N·m {10 kgf·m} [73.76 lbf·ft]).
(1) Place a marking on the cut thread tap at the 50 mm
[1.97 in.] position from the tip.
Cut thread tap
Apply a cutting agent such as Yushiron Cut CS60N P/N: 41091-05200
(Yushiro Chemical Industry Co., Ltd.) or equivalent to
the cut thread tap. Tap the thread hole to the depth of 50
mm [1.97 in.] to remove deposits such as dirt in the
50 mm
hole. [1.97 in.]
Blow air into the thread hole to throughly remove the
chips after tapping.
Cut Thread Tap - Clean

(2) Place a marking on the roll form tap at the 49 mm
[1.93in.] position from the tip.
Rolled thread tap
Apply a cutting agent such as Yushiron Cut CS60N
P/N: 41091-05300
(Yushiro Chemical Industry Co., Ltd.) or equivalent to
the roll form tap. Roll the thread hole to the depth of 49
mm [1.93in.]. Blow air into the thread hole to throughly
remove the chips after rolling. 49 mm
[1.93 in.]
Roll Form Tap - Roll
99089-40100
7-31
(3) Check the thread depth with a thread plug gauge.

Go
Screw in the go gauge into the threaded hole and verify thread gauge
the effective length of the thread.
Screw in the no-go gauge and verify the gauge stops
after several turns.
Thread gauge
P/N: 41091-05400
No-go
thread gauge
Thread Hole Depth - Check

(4) Stamp an identification mark "R" below the matching
mark at the connecting-rod big end for the identifica-
tion of rolled-thread connecting rod.
Identification mark
"R" punch.
Identification Mark "R" - Stamp

4.11 Connecting Rod Cap and Connecting Rod Bolt - Inspect
(1) Check the bolt flange bearing surface of connecting rod
Checking bearing surface
cap and the bearing surface of connecting-rod-cap bolt for scoring
for scoring.
If a scoring is found on the connecting rod cap, remove
the scoring with an oil stone or the like. If a scoring is
found on the bolt, replace the bolt with a new one.
Burr Nicked thread
(2) Check burrs at the chamfer of bearing surface of con-
necting rod bolt and a dent on the thread. Repair if the
burr or dent is found.
Note: Pay attention not to make a scoring or a dent when han-
Connecting Rod - Inspect
dling and storing the cap bolt.
(3) Screw in the cap bolt into the connecting rod by hand to
check the smooth rotation of the bolt. if the bolt rotation
is not smooth, roll the connecting-rod big-end thread
hole.
Note: Note: Clean after roll forming. Check the bolt rotation
if it turns smoothly. Refer to the section "Connecting
Rod Big End Thread Hole - Roll" in "ENGINE BODY
-INSPECT AND REPAIR" for the roll forming of con-
necting-rod big-end thread hole.
7-32 99089-40100
4.12 Connecting Rod Bearing - Inspect and Replace

(1) Replace the connecting rod bearings upper and lower as
a set to a new set whenever disassembled.
(2) Check the inside face contact, scratch caused by foreign
particles, corrosion, deposit on the outside face and oth- Scratch
ers of the used bearing. Flaking
Deposites
(3) Measure the thickness at the center of the used bearing.
If the value is lower than the standard and a damage is
shown on the crankshaft pin, re-grind the crankshaft
and use the under-size connecting rod bearing.
Connecting Rod Bearing - Inspect

Note:(a) Us a micrometer of ball-point type to measure the
connecting-rod bearing thickness.
(b) Grind the crank pin to the specified value in accor-
dance with the under size value of the connecting
rod bearing. Then the lapping is not necessary. Measure the
center of bearing
For the crank pin grinding procedure, refer to
"Crankshaft - Grind" of "ENGINE BODY - IN-
SPECT AND REPAIR".
Under
Nominal Standard
Measurement item size
value value
amount
5.000 mm Connecting Rod Bearing Thickness - Measure
S.T.D
[0.1969 in.]
-0.25 5.125 mm
[-0.0098 in.] [0.2018 in.]
-0.088 to
Thickness at the center of -0.50 5.250 mm -0.068 mm
connecting rod bearing [-0.0197 in.] [0.2067 in.] [-0.0035 to -
0.0027 in.]
-0.75 5.357 mm
[-0.0295 in.] [0.2109 in.]
-1.00 5.500 mm
[-0.0394 in.] [0.2165 in.]
4.13 Connecting Rod Big End Bearing Housing - Inspect and Repair
If and adhesive substance is found on the housing surface of
connecting rod and connecting rod cap, scrape away with a
scraper, sand paper or the like.
Deposites
Connecting Rod Big End Bearing Housing - Inspect

and Repair
99089-40100
7-33
4.14 Connecting Rod Bearing Inside Diameter - Measure

(1) Measure the thickness of new connecting rod bearing,
and check the thickness to be in the standard values.
(2) Install the new connecting rod bearing to the connect- X Y1
ing rod and tighten to the specified torque according to
15° B
the correct tightening procedure. 17 [0.6693] 17 [0.6693] X Y1
(3) Measure the connecting rod bearing inside diameter in 15° Y2
the installed condition at X, Y1 and Y2 directions in 15°
each A an B position. Replace the connecting rod to a
new one according to the procedure (4) if the bearing
inside ellipticity exceeds the limit, or the clearance to
Connecting Rod Bearing Inside Diameter - Measure
the crank pin is below the lower limit of 0.136 mm
[0.0054 in.].
If the clearance to the crank pin exceeds the upper limit
of 0.5 mm [0.020 in.], re-grind the crankshaft, and use
the undersize connecting rod bearing.
Note: Grind the crank pin to the specified value in accor-
dance with the under size value of the connecting rod
bearing. Then the lapping is not necessary.
For the crank pin grinding procedure, refer to "Crank-
shaft - Grind" of "ENGINE BODY - INSPECT AND
REPAIR".

Ellipticity of connecting-rod-bear-
(Max value - min value) ≤ 0.1
ing inside diameter
Clearance between connecting rod 0.136 to 0.500 mm
bearing and crank pin [0.0054 to 0.0197 in.]
4.14.1 Procedure of connecting rod replacement

Replace the connecting rod only if the connecting rod exceeds the limit.
Note: The weight of connecting rod used in each cylinder must be the same weight.
4.15 Inside Diameter of Piston Pin Bushing - Measure

(1) Replace the piston pin bushing with a new one if its
inside face shows such defects as detrimental wear, scar
and discoloration.
Measuring
(2) Measure the inside diameter of piton bushing with a direction
cylinder gauge. If the value exceeds the limit, replace
the piston pin bushing with a new one. Measuring
position

Inside diameter of piston 100.05 to 100.11 mm 100.18 mm
pin bushing inside diameter [3.9390 to 3.9413 in.] [3.9441 in.]
Inside Diameter of Piston Pin Bushing - Measure
7-34 99089-40100
4.16 Piston Pin Bushing - Replace

(1) Use a hand press or the like to pull out the piston pin
bushing. Bushing
(2) Chill the piston pin bushing to -170 to -190°C [-274 to -
310°F] in liquid nitrogen and install in the connecting
rod for expansion fitting to install the piston pin bush-
ing.
Note: Do not allow the bushing to protrude over the connect-
ing rod face.
Installing Position of Piston Pin Bushing

4.17 Weight Difference of Connecting Rod Assembly in One Engine
The weight difference of connecting rod in an engine must
be within the range below to replace the connecting rod.
Connecting rod
check swing motion
Allowable weight difference
range of connecting rod assembly 100 g [3.527 oz.] or less
in one engine
Sliding Movement Between Piston and Connecting

Rod - Check
99089-40100
7-35
5. Crankcase, Main Bearing and Crankshaft - Inspect and Repair

5.1 Slinger and Crank Gear - Inspect and Replace
5.1.1 Slinger - Inspect
Oil seal case
If any defects such as dents, damages, wear and looseness
Oil seal
that can lead to oil leakage are found, replace the slinger
Slinger
with a new one.
5.1.2 Crank Gear - Inspect
If any flaking, wear and defective tooth contact on the gear
tooth or looseness of the gear is found, replace the gear with
Crank gear
a new one.
(Front) (Rear)
Installed Condition of Slinger and Oil Seal
5.1.3 Slinger - Remove
Pull out the slinger from the crankshaft using a gear puller Burner
while warming the slinger with a burner.
Note: Do not heat the slinger for longer than necessary.
Gear puller
Front Slinger - Remove
Burner
Gear puller
Rear Slinger - Remove
7-36 99089-40100
5.1.4 Crank Gear - Remove

Pull out the crank gear from the crankshaft using a gear
puller while warming the gear with a burner after removing Burner
the slinger.
Note: Do not heat the slinger for longer than necessary. Gear puller
Front Crank Gear - Remove
Burner
Gear puller
rear Crank Gear - Remove
99089-40100
7-37
5.1.5 Crank Gear - Install

Heat up the front crank gear and rear crank gear in an elec- Front crank gear
tric furnace with a temperature control function. Adjust the
temperature difference from that of the crankshaft to be 160
to 170°C [320 to 338°F], and install them to crankshaft to
shrinkage fit.
Note: Heat the crank gear to raise the temperature uniformly.
Do not heat the crank gear to the temperature of

200°C [392°F] or higher. Front Crank Gear - Install
Be sure to replace the crank gear to a new one, once
it is removed from the crankshaft, as it might be 1 mm [0.04 in.] Rear crank gear
heated up to 200°C [392°F] or higher for removing.
Installing position of front crank gear

Install the front crank gear to the position where whole cir-
cle of the gear contacts the crank shaft.
Installing position of rear crank gear
Install the rear crank gear aligning its notch to the crank-
shaft dowel pin. Place the gear to be flush with the crank- Dowel pin
shaft thrust force bearing face. Rear Crank Gear - Install
Be sure to install the rear crank gear not to allow the

protrusion from the crankshaft thrust force bearing
face. If the rear crank gear is protruded over the thrust
force bearing face, the thrust plate and rear crank
gear interfere and the crankshaft can not be installed
in the crankcase.
7-38 99089-40100
5.1.6 Slinger - Install

Heat up the slinger in an electric furnace with a temperature Front slinger
Front crank gear
control function. Adjust the temperature difference from
that of the crankshaft to be 110 to 150°C [230 to 302°F],
and install the slinger to crankshaft to shrinkage fit.
Note: Heat the slinger to raise the temperature uniformly.
Do not heat the crank gear to the temperature of

200°C [392°F] or higher.
Be sure to replace the slinger to a new one, once it is Front Slinger - Install
removed from the crankshaft, as it might be heated up
to 200°C [392°F] or higher for removing. Rear slinger 47±0.1
Installing position of front slinger Rear crank gear
Install the front slinger to the position where whole circle of

the slinger contacts the front crank gear.
Installing position of rear slinger
Install the rear slinger to the position where the whole circle
of the slinger inside face is 47±0.1 mm [1.85 ± 0.0039 in.]
from the crankshaft rear end face.
Rear Slinger - Install
99089-40100
7-39
5.2 Crank Pin and Journal Outside Diameters - Measure

(1) Measure the diameter of crank pin and journal in hori- Measuring Measuring
zontal and vertical directions at front and rear positions. direction position
Calculate the roundness and cylindericity based on the

measured values.
(2) If the measured value exceeds the limit, or the crank pin
or journal shows detrimental flaw, grind it to fit to an
under-size bearing of -0.25, -5.0, -0.75 and -1.00 mm Micrometer
[-0.0098, -0.1969, -0.0295 and -0.0394 in.].
Conduct the hardness measurement and magnetic parti-
cle inspection to check the defective hardness, detri-
Crankpin Outside Diameter - Measure
mental flaw and heat crack after the grinding.
Note: For the crankshaft grinding procedure, refer to "Crank- Measuring Measuring
shaft - Grind" of "ENGINE BODY - INSPECT AND direction position
REPAIR".
(3) Replace the crankshaft with a new one, if the limit
value is exceeded using a -1.00 mm undersize bearing,
or the detrimental flaw remains after grinding.
Micrometer
Crank Journal Outside Diameter - Measure
Nominal
value
ø180 mm 0 to -0.025 mm (0.136 to 0.500 mm
Crankpin outside diameter
[7.09 in.] [0.00 to -0.0010 in.] [0.0054 to 0.0197 in.]) Note a
ø200 mm 0 to -0.025 mm (0.147 to 0.500 mm
Crankshaft journal outside diameter
[7.87 in.] [0.00 to -0.0010 in.] [0.0058 to 0.0197 in.]) Note b
Crank pin Parallelism - 0.01 mm [0.0004 in.] or less 0.03 mm [0.0012 in.]
Crank main journal Coaxiality - ø0.01 mm [0.0004 in.] or less 0.03 mm [0.0012 in.]
Roundness - 0.015 mm [0.0006 in.] or less 0.03 mm [0.0012 in.]
Cylindricity - 0.01 mm [0.0004 in.] or less 0.03 mm [0.0012 in.]
10 mm 9.8 to 10.0 mm
Fillet radius -
[0.39 in.] [0.386 to 0.394 in.]
Crank pin and journal
Hs38 to 46
General portion - -
Hard- (HB255 to 311)
ness Induction hardened portion at Hs>72
- -
crank pin and journal (Hv>590)
Note:(a) Value in parentheses shows the value at the clearance to the connecting rod bearing.
(b) Value in parentheses shows the value at the clearance to the main bearing.
7-40 99089-40100
5.3 Crankshaft - Grind

If the outside diameter of crank pin or journal exceeds the
limit, or the crank pin or journal shows detrimental flaw, Induction hardened portion 0.2Ra
grind it to fit to an under-size bearing of -0.25, -5.0, -0.75

and -1.00 mm [-0.0098, -0.1969, -0.0295 and -0.0394 in.].
Crankpin
Grind the crank journal (or pin) to the diameter that fits the
inside diameter of the next undersized main (or connecting) Crank main journal
bearing, then the lapping with bearing is not necessary.

Pay attention not to change the fillet radius and width.
Replace the crankshaft with a new one if the surface hard-
Fillet radius 0.4Ra
ness is significantly lowered. The surface roughness of the
Crankshaft - Grind
crank pin and journal must be ISO -0.25/Ptmax 0.8 (old JIS
0.8S ) after grinding.
Conduct the hardness measurement and magnetic particle
inspection to check the defective hardness, detrimental flaw
and heat crack after the crankshaft grinding. Replace the
crankshaft with a new one, if a defective hardness or heat
crack is shown after grinding.
Crankshaft under-size grinding dimensions

Measurement item Undersize Finishing dimension Roundness Roundness Roundness Cylindricity
0.25 mm 179.725 to 179.750 mm
[0.0098 in.] [7.0758 to 7.0768 in.]
0.50 mm 179.475 to 179.500 mm
Crankpin outside [0.0197 in.] [7.0659 to 7.0669 in.] 0.01 mm
-
diameter 0.75 mm 179.225 to 179.250 mm [0.0004 in.] or less
[0.0295 in.] [7.0561 to 7.0571 in.]
1.00 mm 178.975 to 179.000 mm
[0.0394 in.] [7.0462 to 7.0472 in.] 0.015 mm 0.01 mm
0.25 mm 199.725 to 199.750 mm [0.0006 in.] or less [0.0004 in.] or less
[0.0098 in.] [7.8632 to 7.8642 in.]
0.50 mm 199.475 to 199.500 mm
Crankshaft journal [0.0197 in.] [7.8533 to 7.8543 in.] ø0.01 mm
-
outside diameter 0.75 mm 199.225 to 199.250 mm [0.0004 in.] or less
[0.0295 in.] [7.8435 to 7.8445 in.]
1.00 mm 198.975 to 199.000 mm
[0.0394 in.] [7.8336 to 7.8346 in.]

Hs38 to 46
General portion
(HB255 to 311)
Hardness of crank pin and journal
Induction hardened Hs>72
portion (Hv>590)
99089-40100
7-41
5.4 Crankshaft Runout - Measure

Support the crankshaft at the front and rear main journals
with V-blocks, and measure the crankshaft runout at the
center journal with a dial gauge. If the runout deviates
slightly from the standard values, correct the crankshaft by
grinding. If the value exceeds the standard value consider-
ably, straighten the crankshaft with a press machine. If the
value exceeds the limit, replace the crankshaft with a new 1/2 1/2
one.
If the crankshaft is corrected by grinding or pressing,
inspect the crankshaft for cracks and other harmful damages
Crankshaft Runout - Measure
with the magnetic particle inspection.
Standard Limit
Measurement item Remark
value value
Deflection of crankshaft (cen- 0.08 mm
0.3 mm
ter journal runout when both [0.0031 in.] TIR
[0.012 in.]
end journals are supported) or less
Note: Pay attention that the weight of crankshaft is 1500 kg

[3307 lb.].
5.5 Crankshaft Oil Hole Plug Looseness - Check

Check the crankshaft oil hole plug losseness.
Plug
If loosened, remove the plug, and clean the crankshaft
thread hole and a new plug (41020-01701 with hexagon
socket). Then apply LocTite 271 or equivalent to the thread,
and tighten the plug to the specified torque.
Note: Periphery staking is not necessary.
Crankshaft
hole clogging plug
tightening torque
118 N·m {12 kgf·m}
[87.03 lbf·ft]
Crankshaft Oil Hole Plug Looseness - Check
5.6 Crankcase, Main Bearing Cap Contacting Face - Check

Check the main-bearing contacting face in crankcase for
harmful wear and others.
Contact face Contact face
Crankcase, Main Bearing Cap Contacting Face -

Check
7-42 99089-40100
5.7 Main Bearing - Inspect and Replace

(1) Replace the main bearings upper and lower as a set to a
new set whenever disassembled.
(2) Check the inside face contact, scratch caused by foreign
particles, corrosion, deposit on the outside face and oth-
ers of the used bearing. Scratch
Flaking
Deposites
Bearing Inside Face - Inspect

5.8 Crankcase, Main Bearing Housing Face - Disassemble and Inspect
If and adhesive substance is found on the housing surface of
crankcase and main bearing cap, scrape away with a scraper,
sand paper or the like.
Deposites
Crankcase, Main Bearing Housing Face -

Disassemble and Inspect
5.9 Crankcase Main Bearing Housing Diameter - Measure
Install the main-bearing-cap nut with the specified tighten-
ing torque. Tighten the side bolts to the specified torque.
Measure the main bearing housing diameter in vertical and
the two diagonal directions.
Note: For installation of main bearing cap, refer to "Main
Bearing Cap - Install" of "ENGINE BODY - ASSEM-
BLE". Side bolt Side bolt
883 N·m Main bearing cap 883 N·m
{90 kgf·m} mounting nut {90 kgf·m}
[651 lbf·ft] 63.7 MPa {650 kgf/cm2} [651 lbf·ft]
Nominal
Measurement item Standard value [9246 psi]
value
Inside diameter of main ø210 mm 210.147 to 210.176 mm Crank Case Main Bearing Housing - Measure
bearing housing bore [8.27 in.] [8.2735 to 8.2746 in.]
99089-40100
7-43
5.10 Main Bearing Inside Diameter - Measure

(1) Measure the center thickness of new main bearing, and
check the thickness to be in the standard values.
Nominal Standard Measure

Measurement item the center of bearing
value value
5.000 mm -0.025 mm
Standard
[0.1969 in.] [-0.0010 in.]
-0.25 mm 5.125 mm -0.025 mm
[-0.0098 in.] [0.2018 in.] [-0.0010 in.]
Center thick-
-0.50 mm 5.250 mm -0.025 mm
ness of main
bearing Unde [-0.0197 in.] [0.2067 in.] [-0.0010 in.]
rsize -0.75 mm 5.375 mm -0.025 mm Thickness of Main Bearing - Measure
[-0.0295 in.] [0.2116 in.] [-0.0010 in.]
-1.00 mm 5.500 mm -0.025 mm
[-0.0394 in.] [0.2165 in.] [-0.0010 in.]
Note: Us a micrometer of ball-point type to measure the main

bearing thickness.
(2) Install a new main bearing to the crankcase. Tighten the
Main bearing upper
bearing cap nut with the specified hydraulic pressure,
and tighten the side bolt to the specified torque. Mea-
sure the main bearing inside diameter in vertical and the
Side bolt
two diagonal directions. 883 N·m
Note: For installation of main bearing cap, refer to "Main {90 kgf·m}
[651 lbf·ft]
Bearing Cap - Install" of "ENGINE BODY - IN-
Side bolt
Main bearing lower
SPECT AND REPAIR". 883 N·m Main bearing
{90 kgf·m} cap mounting nut
[651 lbf·ft] 63.7 MPa {650 kgf/cm2} [9238 psi]
Main Bearing Inside Diameter - Measure

(3) If the clearance to the crank journal exceeds the upper
limt of 0.5 mm, re-grind the crankshaft, and use the
undersize main bearing.

Clearance between main bearing 0.147 to 0.500 mm
and crank journal [0.0058 to 0.0197 in.]
Note:(a) Grind the crank journal to the specified value in ac-

cordance with the under size value of the main bear-
ing. Then the lapping is not necessary.
(b) For the crankshaft grinding procedure, refer to
"Crankshaft - Grind" of "ENGINE BODY - IN-
SPECT AND REPAIR".
7-44 99089-40100
5.11 Thrust Plate - Inspect

(1) Replace the upper and lower thrust plates as a set on the
occasion of disassembling.
(2) After the disassembling, check the used thrust plates for
the sliding-face contact, scratches cased by foreign sub-
stance inclusion, corrosion, wear of dowel hole and oth-
ers.
Wear
Scratch, corrosion
Thrust Plate - Inspect

5.12 Crankcase Oil Hole - Inspect
Check the crankcase oil hole for clogging and others.
5.13 Cylinder Liner Water Jacket - Inspect

Check the cylinder liner water jacket in crankcase for detri-
mental corrosion and damage.
Repair with repairing agent or others if detrimental corro-
sion is found. Install a cylinder liner and conduct a water
pressure test for leak check.
99089-40100
7-45
5.14 Crankcase Top Seal Face - Repair

Reface the crankcase top seal face to the cylinder liner when
the cylinder liner is removed in overhauling.
Assemble the cylinder liner polisher and crankcase polisher
to one body, and polish the crankcase top seal face with the
polisher. Crankcase polisher Cylinder liner
(Recommended polishing interval: every 24000 hours) P/N: 41091-06700 polisher
P/N: 41091-06600
Crankcase
Combination of Cylinder Liner Polisher and Crankcase

Polisher
5.14.1 Preparation of polishing
double-faced tape
the sandpaper to the same width (15 to 25 mm [0.59 to [0.59 to 0.98 in.]
0.98 in.]) as that of the double-faced tape. Stick the Cut.

mm [1.18 to 1.57 in.] in length. Cut one side of sandpa-
Sand paper
per to fit to the crankcase polisher inner periphery. Stick
12 pieces of sandpaper to the crankcase polisher align-
ing its side shape to the polisher periphery.
Note: Pay attention to keep the crankcase polisher surface to Width of
be free from the scar and hitting mark during the han- double-faced tape
15 to 25 mm
dling and storing. [0.59 to 0.98 in.] 30 to 40 mm
[1.18 to 1.57 in.]
The top seal face may be defective if the polishing is
done with a scar or hit mark on the polishing surface. inside diameter.
to be flush with
the inside diameter.
Crankcase
polisher
Sandpaper - Stick
7-46 99089-40100
5.14.2 Procedure of crankcase top seal face polishing

Place the crankcase polisher squarely to
Hold firmly the bars of crankcase polisher with both hands. the crankcase upper sealing face,
then press and slowly rotate the polisher.
Rotate the polisher by pressing it squarely. Rotate the pol- Reverse the rotational direction once
isher slowly to avoid local polishing and waggle on the in every ten turnes.
crankcase top seal face.

Reverse the rotating direction at approx every ten turns.
clogged. Replace the sandpaper timely when it is
worn. Sand paper
Procedure of Crankcase Top Seal Face Polishing
use a lapping compound (for valve seat) as it dam-
age the crankcase polisher.
(c) Grind the crankcase top seal face with 240 grid sand
paper when the asperity of the sealing face is shal-
low.
5.14.3 Crankcase Top Seal Face - Check

Contact check gauge
P/N: 41091-06900
The engine may cause a gas leak during the engine

operation if the polishing of top seal face is defective. Apply a thin coat of
lead-free contact checker.
(1) Apply a thin coat of contact checking compound (lead ࢤ࣮ࢪ࡛
Check the contact
ᙜࡓࡾࢆ☜ㄆ
with the gauge.
check the face contact of gas sealing surface.
Crankcase upper side
Note: Repeat the polishing if the contact is not even on the
whole top seal face.
Crankcase Top Seal Face - Check
(2) Use 800 grid sandpaper for finish-polishing after the
even contact on the whole top seal face is verified.
(3) Check the top seal face again for the even whole face Before polishing.
contact with the contact gauge. Defective contact position
Polishing
first stage. Contact face check
Polishing
completed.
Polish the upper sealing face to make
a whole face contact to the gauge
with lead-free contact checker
Seal Face Contact - Judge
99089-40100
7-47
1. Upper Main Bearing, Crankshaft and Crankcase - Assemble ............................. 8-3
1.1 Upper Main Bearing - Install ..................................................................................................... 8-3
1.2 Crankshaft - Install.................................................................................................................... 8-4
1.3 Lower Main Bearing Shell and Thrust Plate - Install................................................................. 8-5
1.4 Main Bearing Cap - Install ........................................................................................................ 8-6
1.5 Crankcase - Turn Over ............................................................................................................. 8-8
1.6 Crankshaft End Play - Measure................................................................................................ 8-9
1.7 Oil Pan - Install ....................................................................................................................... 8-10
2. Cylinder Liner, Piston, and Connecting Rod - Assemble .................................. 8-11
2.1 Cylinder Liner - Install ............................................................................................................. 8-11
2.2 Cylinder Liner Inside Diameter - Measure .............................................................................. 8-12
2.3 Anti-polish RIng - Check ......................................................................................................... 8-13
2.4 Piston Pin - Install ................................................................................................................... 8-13
2.5 Snap Ring - Install .................................................................................................................. 8-14
2.6 Piston Ring - Install................................................................................................................. 8-14
2.7 Preparation to Install Piston.................................................................................................... 8-15
2.8 Connecting-Rod Bearing - Install............................................................................................ 8-16
2.9 Piston - Install ......................................................................................................................... 8-17
2.10 Preparation of connecting-rod cap installation........................................................................ 8-18
2.11 Connecting Rod Cap - Install.................................................................................................. 8-19
2.12 Connecting Rod Front-Back Direction Clearance - Check ..................................................... 8-21
3. Front Mechanism - Assemble............................................................................... 8-22
3.1 Idler Gear - Install ................................................................................................................... 8-22
3.2 Idler Gear Backlash - Measure ............................................................................................... 8-22
3.3 Front Gear Case - Assemble .................................................................................................. 8-22
3.5 Front Gear Case - Install ........................................................................................................ 8-24
3.6 Backlash Between Crank Gear and Idler Gear - Measure ..................................................... 8-24
3.7 Oil Seal Retainer - Install ........................................................................................................ 8-24
3.8 Oil Seal - Install....................................................................................................................... 8-25
3.9 Damper - Install ...................................................................................................................... 8-26
3.10 Thermo Label - Stick............................................................................................................... 8-27
3.11 Damper Cover - Install............................................................................................................ 8-27
4. Rear Mechanism - Assemble ................................................................................ 8-28
4.1 Camshaft - Assemble ............................................................................................................. 8-28
4.2 Camshaft - Install.................................................................................................................... 8-29
4.3 Idler Gear and Idler Shaft - Install........................................................................................... 8-29
4.4 Engine - Turning ..................................................................................................................... 8-29
4.5 Timing Gear Train Matching Marks - Check ........................................................................... 8-30
4.6 Inspection before installing the timing gear case.................................................................... 8-30
4.7 Backlash Between Idler Gear and Crank Gear - Measure ..................................................... 8-32
4.8 Timing Gear Case - Install ...................................................................................................... 8-32
4.9 Camshaft Gear - Install........................................................................................................... 8-33
4.10 Backlash Between Camshaft Gear and Idler Gear - Measure................................................ 8-33
4.11 Camshaft Bearing and Camshaft Gear Cover - Install ........................................................... 8-33
4.12 Tachometer Shaft and Tachometer Installation Cover - Install............................................... 8-34
4.13 Oil Seal and Oil Seal Case - Install......................................................................................... 8-34
4.14 Flywheel - Install ..................................................................................................................... 8-35
4.15 Flywheel Face and Radial Runouts - Measure....................................................................... 8-35
99089-40100
8-1
5. Cylinder Head and Valve Mechanism - Assemble .............................................. 8-36

5.1 Tappet and Tappet Guide - Install .......................................................................................... 8-36
5.2 Bushings on Crankcase Upper Face - Install ......................................................................... 8-36
5.3 Copper Tube - Install .............................................................................................................. 8-37
5.4 Valve Stem Seal - Install......................................................................................................... 8-37
5.5 Valve and Valve Spring - Install.............................................................................................. 8-38
5.6 Valve Sinkage - Measure........................................................................................................ 8-39
5.7 Cylinder Head Assembly - Install............................................................................................ 8-39
5.8 Cylinder Head Setting Nut - Install.......................................................................................... 8-40
5.9 Bridge - Install......................................................................................................................... 8-41
5.10 Clearance Between Valve Bridge and Valve Cotter - Inspect ................................................ 8-41
5.11 Rocker Shaft Assembly and Push Rod - Install ...................................................................... 8-42
5.12 Both inlet and both exhaust valve heights by valve bridge - Adjust........................................ 8-43
5.13 Valve Clearance - Check and Adjust ...................................................................................... 8-44
5.14 Fuel Injection Timing - Inspect and Adjust.............................................................................. 8-47
5.15 Valve Timing - Inspect ............................................................................................................ 8-50
5.16 Nozzle Assembly - Install........................................................................................................ 8-51
5.17 Rocker Cover - Install ............................................................................................................. 8-51
8-2 99089-40100
1. Upper Main Bearing, Crankshaft and Crankcase - Assemble

1.1 Upper Main Bearing - Install
(a) Do not apply engine oil to the back face of the upper main bearing shell and the main bearing housing in the
crankcase when installing the upper main bearing. Wash those surfaces to remove foreign material, oil, and
grease using a washing solvent before installing the main bearing.
(b) When installing the upper main bearings, be careful not to confuse the upper shells with the lower shells.
The upper main bearing shell can be identified by a machined oil hole, and the lower main bearing shell has no
oil hole nor groove.
The main bearings can be installed confusing the shells upside down, but such installation could damage the
crankshaft. Be very careful not to confuse the upper shell with the lower shell. Be careful not to install the main
bearings upside down.
(c) Be careful not to damage the bearing when installing.
(1) Reverse the crankcase using a turn over table or the

like. Lug
Upper main bearing
(2) Clean the main bearing housing and the main bearing
cap mating surfaces using cleaning solvent, and make Oil hole
Front
sure that these surfaces are free from any foreign mate-
rial. Lug slot
(3) Make sure that the main bearing is free from damage or Crankcase
Oil groove
contamination.
(4) Fit the upper main bearing shell in the crankcase bore
Rear
by aligning the lug on the shell with the lug slot in the
Upper Main Bearing - Install
crankcase.
Note:(a) Make the crush heights even.
(b) The oil hole in the upper main bearing will be
aligned with the oil hole in the crankcase by fitting
the lug of the upper shell into the lug slot in the
crankcase.
(5) Apply an even coat of engine oil to the inside surface of
each upper main bearing.
99089-40100
8-3
1.2 Crankshaft - Install

(1) Reverse the crankcase using a turn over table or the
like.
(2) Make sure that the inside face of upper main bearing
installed in the crankcase is lubricated with an even
coat of clean engine oil.
(3) Wash the crankshaft thoroughly with cleaning oil and
clean it completely by blowing compressed air. Then, After cleaning, apply
apply an even coat of clean engine oil to the crankshaft small amount of
engine oil to journal.
journals.
Note: When washing crankshaft, be sure to thoroughly clean
the crank journals, crankpins, and oil holes so that they
After cleaning, blow
are free from foreign substances, dust and dirt. compressed air.
Crankshaft - Clean
(4) Lift the crankshaft keeping it in a horizontal attitude,
and slowly install into the crankcase.
Crankshaft Weight
Note: When lifting the crankshaft, use fiber slings or pads to Approx.1500kg [3307 lb.] Rear
avoid any damages to the crankshaft. Main
bearing
upper
Front
Thrust
plate upper
Crankshaft - Install
8-4 99089-40100
1.3 Lower Main Bearing Shell and Thrust Plate - Install
(a) Do not apply engine oil to the outer periphery of the lower shells and lower main bearing housing when installing
the lower main bearing shells. Install the main bearing only after cleaning off foreign material, oil and grease
from these surfaces using a cleaning solvent.
(b) When installing lower main bearings, be careful not to confuse the upper shells with the lower shells. The upper
main bearing shell is identified by machined oil hole. The lower main bearing shell has no oil hole nor groove.
The main bearings can be installed confusing the shells upside down, but such installation could damage the
crankshaft. Be very careful not to confuse the upper shell with the lower shell. Be careful not to install the main
bearings upside down.
Install the main bearing not to damage the bearing.
(c) Be careful not to damage the thrust plates when installing.
(d) When installing thrust plates, be careful not to confuse the upper plate with the lower plate. The upper thrust
plate has no dowel pin hole. And the lower thrust plate has dowel pin holes.
(1) Install the upper thrust plates onto the front and back Upper thrust
Lower main bearing
faces of the rearmost journal through the clearances plate
Front
between the crankcase and the crankshaft. Lug
Note: Install the thrust plate to place its oil grooves facing Lug slot
outward. Upper thrust
plate Assembly number
Apply clean engine oil to the bearing surface.
(Matching mark)
(2) Install the lower main bearing shell by aligning the lug Lower thrust
with the lug slot in the main bearing cap. Rear plate
Note: Make the crush heights even. Lower thrust Assembly number Main bearing
plate (Matching mark) Cap
(3) Apply a small quantity of clean engine oil evenly to the
Main Bearing Cap Bolt - Install
inside face of each lower main bearing.
(4) Check the matching marks on the upper and lower
thrust plates. Install the lower thrust plate to the rear-
most main bearing cap aligning the thrust plate to the
dowel pins.
99089-40100
8-5
1.4 Main Bearing Cap - Install

(1) Make sure that the lower main bearing shell installed in
the main bearing cap is applied with an even coat of Rear
￢￢
Front mark F
clean engine oil.
(2) Install an eye bolt (M12 × 1.75) to the main bearing cap
and lift the cap.
(3) Make sure that the "F" mark on the bearing cap facing
front, and install the cap slowly to the crankcase.
Front
Main Bearing Cap - Install

(4) Keep the main bearing in a lifted condition, and apply
Moly LG Grease No. 2 (SUMICO) or equivalent to the
side bolt threads on the left side seen from the engine
flywheel. Tighten the bolt to the specified snug torque.
(5) Apply Moly LG Grease No. 2 (SUMICO) or equivalent
to the side bolt threads on the right side seen from the
engine flywheel. Tighten the bolt to the specified snug Right side
Left side
bolt
torque. bolt
392N・m
196N・m
{40kgf・m}
Note: The main bearing is tighten in a left drawn position. {20kgf・m}[145 lbf・ft]
[289 lbf・ft]
The snug torques of right and left side bolts are differ-
Side Bolt - Tighten Snugly
ent.
(6) Remove the eye bolt from the main bearing cap.
(7) Apply Moly LG Grease No.2 (SUMICO) or equivalent
to the threads of main bearing nut. Install the nut to the
main-bearing cap setting stud.
8-6 99089-40100
(8) Install the main bearing cap nut with the hydraulic jack,
Cap hydraulic jack
hydraulic hand pump, hydraulic hose and shaft. P/N:41091-03500
Air vent plug Hydraulic hose
Note: Before applying the hydraulic pressure to the cap hy- P/N:05312-02100
Shaft
P/N:41091-02600
bleed air and oil from the jack, retract the jack, then P/N:41091-02001
(a) Apply the hydraulic pressure of cap oil jack at a time, and install the two main bearing cap nuts at a time. If the
pressure is applied to one after the other, the main bearing cap or stud will be damaged.
(a)Install the foot piece of cap hydraulic jack, and fully

tighten the hydraulic jack (with the piston rod).
Piston rod
P/N: 41091-03500 Main bearing
stud bolt
Foot piece
Main bearing
cap setting nut Main bearing
cap
Cap Hydraulic Jack - Install
99089-40100
8-7
(b)Connect the hydraulic hose from the hydraulic hand Hydraulic pressure
Hydraulic hose
pump to hydraulic jack, and apply hydraulic pressure 63.7 MPa {650 kgf/cm2}
[9246 psi] P/N:05312-02100
of 63.7 MPa {650 kgf/cm2} [9246 psi] to extend the
Stroke limit line
stud bolt. Hydraulic (Red line)
Approx. 5 mm (Elongation direction)
hand
pump [0.20 in.]
P/N:41091-02001
Do not extend the cap hydraulic jack to exceed the
splash when the cap hydraulic jack is extended over
the limit line. This may cause personal injury. Apply Hydraulic Pressure to the Cap Jack.
cap nut, and snug tighten the nut to the main bearing
cap.
Remove the shaft. Shaft
P/N:41091-02600

(d)Tighten the left side bolt seen from rear to the speci-
fied torque. Then tighten the right side bolt seen from
rear to the specified torque.
(e)Release the hydraulic pressure and remove the cap
hydraulic jack.
883N･m 883N･m
{90kgf･m} {90kgf･m}
Side Bolt - Tighten

1.5 Crankcase - Turn Over
Place the crankcase on a turn over table and reverse the
crankcase to the proper attitude.
Apply Moly LG Grease No.2 (SUMICO) to the screw-in Cylinder head
threads of cylinder head setting stud after turning over the mounting stud bolt
crankcase. Tighten the stud to the specified torque.
Screw-in thread tightening

torque
196N・m{20kgf・m}
[145 lbf・ft]
Apply Moly Grease No.2 or
equivalent to threads.
Cylinder Head Setting Stud - Install
8-8 99089-40100
1.6 Crankshaft End Play - Measure

Tighten the reamost bearing cap nuts and side bolts in the +0.035
100 ( 0 ) mm
proper procedure. Then measure the end play (clearance
+0.0014
[3.94 ( 0 ) in.]
between the width of crankshaft thrust bearing faces and the

width of thrust plates installed on the bearing cap) of the
crankshaft.
(1) Apply the dial gauge plunger to the rear end face of
crankshaft.
(2) Insert two bars from both sides to the clearance
between the crankshaft balance weight and the crank-
case through the rearmost crankcase inspection win-
Crankshaft Thrust Bearing Face
dows.
(3) With the bars, move crankshaft fully to front and rear,
and read each measurement. The end play is the differ-
ence between the front and rear measurements. Replace
Thrust plate
the thrust plates if the end play of crankshaft exceeds -0.19
9(-0.22 )
-0.0075
the limit. [0.35(-0.0087 )] -0.19 -0.0075
9(-0.22 ) [0.35(-0.0087 )]
Main bearing cap
82( )
0
-0.035
(rearmost end)
Measurement item Standard value Limit value 0
[3.22( -0.0014 )]
0.38 to 0.51 mm 0.60 mm -0.380 -0.015
100(-0.475 ) [3.94(-0.019 )]
Crankshaft end play
[0.0150 to 0.0201 in.] [0.0236 in.]
Unit: mm [in.]
(4) If the limit is still exceeded after installing the new Dimensions Around Thrust Plate
thrust plates, use the oversize thrust plates.
Note:(a) Three oversizes of +0.25, +0.50 and +0.75 mm
[+0.0098, +0.0197 and +0.0295 in.] are provided.
(b) In general, the rear thrust plates wear faster than the
front thrust plates. Therefore, in most cases, the cor-
rection is achieved by replacing the rear thrust
plates with a next oversize ones.
(5) If the end play becomes smaller than the standard value
with the oversize thrust plates, re-grind the thrust bear-
ing surface of crankshaft and use the oversize thrust Bar
plates. Crankshaft End Play - Measure
Re-grinding dimensions of crankshaft thrust bearing face

Oversize Oversize
Oversize plate on one plates on both Tolerance
side sides
0.25 [ 100.25 mm 100.50 mm
+0.0098 in.] O.S [3.9468 in.] [3.9567 in.]
+0.035
0.50 100.50 mm 101.00 mm 0 mm
[+0.0197 in.] O.S [3.9567 in.] [3.9764 in.] +0.0014
[ 0 in.]
+0.75 100.75 mm 101.50 mm
[+0.0295 in.] O.S [3.9665 in.] [3.9961 in.]
99089-40100
8-9
1.7 Oil Pan - Install

(1) Install the oil pan gasket to the oil pan aligning with
dowel pins on the bottom face of crankcase.
The oil pan gasket is divided. Apply sealant (Three-
Bond 1215 or equivalent) to the joints, then install the Oil pan gasket
Crankcase
gasket.
(2) Lift the oil pan with a hoist, and install the oil pan to the
Cut the gasket,
crankcase aligning with dowel pins. Tighten the oil pan Apply ThreeBond 1215 Oil pan
mounting bolts to the specified torque. or equivalent. 57 N·m
(3) Cut the gasket protruding from the front end of crank- {5.7 kgf·m}
[41 lbf·ft]
case and oil pan with a cutter to make the gasket end
Cutting Face of Oil Pan Gasket
face to be flush with the front end face of crankcase and
oil pan.
Oil pan gasket
(4) Apply sealant (ThreeBond 1215) to the gasket end after Rear
the cutting, and install it to the front gear case. Dowel pin hole
Front Dowel pin hole
Apply ThreeBond 1215 Rear

or equivalent to gasket
separating section.
Crankcase
Gasket for oil pan
Front
Oil pan Oil pan
Oil pan weight mounting bolt
Approx. 380 kg [838 lb.] 57 N·m {5.7 kgf·m}
[41 lbf·ft]
Oil Pan - Install
8-10 99089-40100
2. Cylinder Liner, Piston, and Connecting Rod - Assemble

2.1 Cylinder Liner - Install
(1) Apply grease to the O-ring grooves on cylinder liner.
And, install new O-rings to the cylinder. Hanger bolt
(2) Install the plate A to the cylinder liner upper face, and
Wire
plate B to the bottom face with studs and nuts. Hitch a
sling to the hanger bolt an lift the liner with a hoist. Plate A
Apply ThreeBond 1215 or equivalent to the bottom Cylinder
face of liner flange and the fitting face below the Apply ThreeBond liner
1215 or equivalent to Stud bolt
flange. Then install the liner to the crankcase. liner flange bottom face
(3) After installing the cylinder liner into the crankcase, tap and fitting face below Apply grease
liner flange to O-ring.
the plate A to seat the liner flange closely on the crank-
Cylinder Liner - Lift
case.
Note: Apply pressing force on the cylinder liner flange. Nut Wire
(4) Remove the excessive sealant protruded from the cylin- Plate A
Hanger bolt
der liner flange after the applied sealant is fully dried. Cylinder liner
Inserting direction
Note: Thoroughly remove the excessive sealant around the
water passage bushing.
Crank
(5) Apply water leak test at a test Pressure of case
0.4MPa{4kgf/cm2} [57 psi] to verify the air tightness. Apply greas
plate B to O-ring.
Stud bolt
Nut
Cylinder Liner - Install
Plate A
Cylinder Liner - Install
99089-40100
8-11
2.2 Cylinder Liner Inside Diameter - Measure

Measure the inside diameter of the cylinder liner in the pis-
ton pin direction and its perpendicular direction at the upper Right angle to the
[2.1]
55
55
Upper piston pin
[7.87]
(step-worn position), middle and lower positions. If the
200
200
[15.75]
Pin direction
value exceeds the limit, replace the cylinder liner with a
400
400
Medium
new one.
Lower
Measurement Nominal
item value
Cylinder liner ø240 mm 240.000 to 240.046 mm 240.400 mm Measuring direction
inside diameter [9.45 in.] [9.4488 to 9.4506 in.] [9.4645 in.]
Measuring Points of Cylinder Liner Inside Diameter

Cylinder Liner Inside Diameter - Measure
(With anti-Polish Ring)
Measure the inside diameter of the cylinder liner in the pis-
ton pin direction and its perpendicular direction at the upper
[2.17]
[0.79]
(step-worn position), middle, lower and anti-polish ring
55
20
installed positions. If the value exceeds the limit, replace the Anti-polish ring
Upper
200 [7.87]
installing position
cylinder liner with a new one.
400 [15.75]
Middle
Measurement Nominal
item value Lower
Cylinder liner
ø240 mm 240.000 to 240.046 mm 240.400 mm
inside diameter
[9.45 in.] [9.4488 to 9.4506 in.] [9.4645 in.]
(3 places)
Anti-polishing Unit mm [in.]
ø255 mm 255.000 to 255.056 mm 255.400 mm
Assembled Inside Diameter with Anti-Polish Ring - Measure
[10.04 in.] [10.0394 to 10.0416 in.] [10.0551 in.]
inside diameter
8-12 99089-40100
2.3 Anti-polish RIng - Check

Clean the anti-polish ring after disassembling. Apply an inspection such as a liquid penetrant inspection or others to check the
detrimental damage. Replace it with a new one if it is defective.
2.3.1 Anti-polish Ring Dimension - Measure
The measured values of anti-polish ring sometimes exceed the standard values becuse of its thin-wall cylindrical
structure. The measured values below are references and if the average of measured values exceeds the limit,
replace the ring with a new one.
Measure the anti-polish ring outside diameter with a micrometer and inside diameter with a cylinder gauge.
Measurement item Standard value (reference) Limit value

+0.072 +0.0028
Anti-polish ring inside diameter ø238 ( 0 ) mm [ø9.37 ( 0 ) in.] 238.400 mm [9.3858 in.]
4 places, average
-0.06
Anti-polish ring outside diameter ø255 (-0.10) mm 4 places, average 255.400 mm [10.0551 in.]
2.3.2 Anti-polish Ring - Inspect Visually

Upper
The lower part of ant-polish ring may interfere with the pis-
Visual inspection
ton, and is sometimes damaged. Replace the ring with a new
one if it is defective.
Anti-polish ring
Lower
Ant-polish Ring - Inspect Visually
2.4 Piston Pin - Install
(1) Clean the connecting rod with air blow, cleaning agent
or the like before assembling the piston and connecting Warm by piston heater Hanger Piston
rod. or hot water.
Remover
Bolt
Note: Thoroughly clean the thread hole, oil hole and serra- P/N:41091-10600
tion surface of the connecting rod. Piston

(2) Fix the connecting rod with a vise. Install the piston
remover hanger to the piston and lift the piton with a
Connecting rod
hoist.
(3) The piston and piton pin are assembled in a clearance Vise
fit. Raise the temperature of piston in hot water. Apply
Piston - Install
clean oil evenly on the piston pin and insert it into the
piston to connect the piston and connecting rod.
Hanger
Bolt
Piston pin
Piston
Piston Pin - Insert
99089-40100
8-13
2.5 Snap Ring - Install

(1) Install the snap ring in the snap ring groove in piston
with snap ring priers.
Note:(a) Pay attention to the tension and fitting condition of Snap ring
snap ring when installing the snap ring.
(b) Install the snap ring so that their its end gap faces to- Snap ring
Pliers
ward the bottom of the piston.
(2) Verify the connecting rod to swing smoothly with
looseness.
Snap Ring - Install

2.6 Piston Ring - Install
Every piston ring has an upper face mark near the end
gap. Be careful not to install the piston rings upside
down. If the piston rings are assembled incorrectly, it Top face mark
results in defects such as engine seizure. No. 1 compression ring
(1) Use ring priers to install the piston ring. No. 2 compression ring
(2) Place the coil spring joint at a 180°opposite position of
No. 3 compression ring
the ring gap of oil ring.
Oil ring
Combination of Piston and Piston Ring
For marine and
For emergency-use
Upper mark continuous-use
engines
engines
No. 1 ring RN RNB Coil spring joint
No. 2 ring RT RT
No. 3 ring R R
Note: The piston-ring upper face mark is based on the table 180°
above. However it may be different in some specifica-
tions. Contact your MHI dealer for the confirmation.
Oil ring gap

Combination of Oil Ring and Coil Spring
8-14 99089-40100
2.7 Preparation to Install Piston

(1) When the cylinder, in which the piston is to be assem-
bled, is in the right bank, rotate the crankshaft to place
the pin to approx. 50°position before the top dead cen-
ter. In the left bank, to approx. 50°position after the top
dead center. Left-bank Right-bank
cylinder cylinder
Top dead Top dead
center position center position
ATDC
ATDC approx.
approx. 50°
50° BTDC approx. 50°
Position of Crankpin - Adjust
(2) Clean the cylinder inside face and crank pin with waste
cloth, and apply an even coat of clean engine oil.
Engine oil
apply.
Cylinder liner
Cylinder Inside Face - Clean and Lubricate
2.7.1 Cylinder liner (with anti-polish ring)
Do not assemble the piston into liner without the anti-polish
ring or after installing the anti-polish ring. Install the piston
installer for anti-polish-ring type liner on the cylinder. Clean
the cylinder inside face, piston installer and crank pin, then
apply engine oil evenly.
Piston installer
P/N:41091-02300
Cylinder Liner (with anti-polish ring)
99089-40100
8-15
2.8 Connecting-Rod Bearing - Install
Do not apply engine oil to the connecting-rod bearing

Lug slot
outside face and connecting-rod big-end bearing
housing faces when installing the connecting-rod
bearing. Clean these parts to remove foreign material
and contamination with waste cloth, then install the
connecting-rod bearing.
Upper connecting
(1) Clean the connecting-rod big-end bearing housing, rod bearing
thread hole and serration surface with a cleaner and
Upper Connecting Rod Bearing - Install
waste cloth, and check the adhesion of foreign sub-
stances and others.
(2) Check the upper rod bearing for flaw and contamina-
tion.
(3) Install the upper rod bearing to the connecting-rod big
end aligning to the lug slot, and apply an even coat of
clean engine oil to the bearing inside face.
Note: Make the crush heights even after installing the bear-
ing.
8-16 99089-40100
2.9 Piston - Install
Right
To prevent the oil ring from damaging by impact No. 1 ring gap No. 2 ring gap
shock, slowly insert the piston.
(1) Apply an even coat of clean engine oil to the piston Piston pin direction
Front Rear
periphery and all piston rings. Place the ring end gaps
diagonally with each other avoiding the piston pin
direction and piston thrust direction.
No. 3 ring gap Oil ring gap
Left
Piston Ring Gap - Adjust Position
(2) Fix the piston remover hanger to the piston top thread
holes with bolts. Piston Hanger
Installer
Fix the piston remover guide piece to the connecting- P/N:41091-04400
Bolt Piston
rod big-end thread hole with bolt. Remover
Place the piston installer on the cylinder liner top. Matching P/N:
mark Guide piece 41091-10600
Bolt
Camshaft

Piston and Connecting Rod (Right Bank) - Insert
(3) Lift the piston and connecting rod with a hoist. Place
the connecting-rod match mark to the cam shaft side. (For the right-bank cylinder)
Insert the piston slowly into the cylinder, and stop it

near the piston TDC position.
Note: Be careful not to cause damages such as scuff and bend
to the piston ring when inserting the piston and con-
necting rod.
Forward rotation

Crankshaft and Connecting Rod - Connect
(Right bank)
(4) Fit the crank pin to connecting-rod big end by rotating
the crankshaft in reverse rotation for the right bank cyl-
inder and forward rotation for the left bank cylinder
with the turning gear by adjusting the piston and con-
necting rod height with a hoist.
Note: Pay attention not to hit the crank pin with the connect-
ing rod to prevent the crank pin from damaging.
(5) Remove the guide piece of piston remover.
(6) Rotate the crankshaft in the forward direction to a crank
angle position where the connecting-rod cap is easily
Preparation of connecting-rod cap installation
installed to the connecting-rod big end through the
(right bank)
crankcase inspection window by rotating the turning
gear.
99089-40100
8-17
(7) Check the position of upper connecting-rod bearing by

Upper Connecting rod
hand through the crankcase inspection window. bearing
If the bearing shell is not positioned properly, push the
bearing upward by hand to correct the position.
Crush heights at both ends

are to be even.
Upper Connecting-Rod Bearing Installed Position -
Check
2.10 Preparation of connecting-rod cap installation
Do not apply engine oil to the connecting-rod bearing Lug slot

outside face and connecting-rod big-end bearing
housing faces when installing the connecting-rod
bearing. Clean these parts to remove foreign material
and oil films with a cleaner and waste cloth, then
install the connecting-rod bearing.
Dowel pin
(1) Clean the connecting-rod-cap bearing housing and ser-
ration surface with a cleaner and waste cloth, and check
Lower Connecting-Rod Bearing - Install
the adhesion of foreign substances and others.
(2) Check the lower rod bearing for flaw and contamina-
tion.
(3) Install the lower rod bearing to the connecting-rod cap
aligning to the lug slot, and apply an even coat of clean
engine oil to the bearing inside face.
Note:(a) Check the connecting rod cap for the installation of
dowel pin which aligns with the connecting rod.
(b) Make the crush heights even after installing the
lower bearing.
8-18 99089-40100
(4) Apply engine oil of SAE #30 or equivalent to the serra-

tion.
to the flange bearing face and threads of connecting-rod
bolt.
Note:(a) When a grease or paste form molybdenum-disulfide
lubricant is used as Moly LG Grease No. 2 (SUMI-
CO), the lubricant must be free from the foreign
substance inclusion such as cutting chips. Apply an
even coat of lubricant with a clean brush.
(b) The following spray type molybdenum-disulfide
lubricants are substitutes of the Moly LG Grease
No. 2 (SUMICO).
Moly Paste Spray (SUMICO)
Molycoate G Rapid Spray (Dow-Coning)
Rocol Assembly and
Running-in Spray (ROCOL)
Pay attention not to allow dust or metallic particles to

enter when applying the molybdenum-disulfide lubri-
cant to the connecting rod.
2.11 Connecting Rod Cap - Install
When installing the connecting rod cap, make sure that dust or metal particles are not caught in the cap serrations,
bolt seating surfaces and the bolt threads.
The connecting-rod bolt for 11mm-pitch serration must be
used in combination with a hard washer. 11 mm [0.43 in.] pitch serration, connecting rod bolt, hard washer
(long) 212 mm [8.35 in.]

Measurement item Part number
41019-00800
Lo
(Step under flange, 2
ng (Steps under flange, 2 places)
Connecting-rod place) (short)
11 mm [0.43 in.] bolt
41019-60300
Serration Sh
(Step under flange, 2
ort
place) 172 mm [6.77 in.]
Hard washer 41019-01600
Connecting-Rod Bolt, Hard Washer
99089-40100
8-19
2.11.1 Assembling of 11 mm Serration Type Connect-

Identification mark
ing Rod
Connecting rod
(1) Assemble the hard washer to the connecting rod.
Matching mark
(2) Install the connecting-rod cap to the connecting rod.
Check the face
Check the alignment of match marks. And the side face to be flat.
of connecting rod must be flush with the side face of Connecting
connecting-rod cap. rod cap
(3) Tighten the connecting-rod bolts to the specified initial
torque following the tightening sequence and dividing Connecting-rod bolt (Right bank, seen from
Hard washer the engine front)
the tightening in several steps.
Installed Condition of Connecting Rod Cap - Check
(4) Loosen the connecting-rod bolts until they can be
turned by hand. (Right bank: seen from the engine front)
4 1
(5) Then tighten the connecting-rod bolts to the specified
snug torque following to the tightening sequence in a
few steps.
View A
(6) Referring to a corner of 12 corners of the connecting-
rod bolt head, mark 2 points with 105°distance (3.5 cor-
ners of 12 corners) on the cap bearing face. 2 3 A
Make one mark on the connecting-rod bolt flange align- Connecting-rod bolt Connecting-rod bolt
ing with one of the cap bearing face mark which is the hand-tightening torque Snug tightening (close contact)
441N・m{45kgf・m}[325 lbf・ft] torque 245N࣭m{25kgf࣭m}[181 lbf・ft]
tightening start point. Tightening Sequence of Connecting Rod Cap Bolts
Note: Use a fine marker to make the marks.
(7) Tighten the connecting-rod bolts to the marked 105 ± 3.5 corners of 12 corner bolt head
5°point following to the tightening sequence.
Note: Set the torque wrench to 539 N·m {55 kgf·m} [397.54
lbf·ft] (depending on the coating agent, 490 N·m {50
kgf·m} [361.40 lbf·ft] or 588 N·m {60 kgf·m} [433.68
lbf·ft]).
Raise the torque wrench setting if the tightening can
not reach the tightening angle of 105 ± 5°. Then tighten
again.
If the tightening angle exceeds the 105 ± 5°, loosen the Make Marks on the Cap Bearing Face and
connecting-rod bolts and lower the torque wrench set Connecting-rod Cap-bolt Flange.
torque. Repeat the tightening from item (4).

105 ° ± 5 °
The torque wrench setting is just a reference. The
tightening angle of the bolt is the tightening standard.
Tightening with the Controlled-angle Method
8-20 99089-40100
2.12 Connecting Rod Front-Back Direction Clearance - Check

Slide the connecting-rod cap front and back to check the
clearance.
Connecting-Rod Front-Back Direction Clearance -

Check
99089-40100
8-21
3. Front Mechanism - Assemble

3.1 Idler Gear - Install
(1) Install the snap ring, spacer and bearing to the idler
Snap ring
gear.
Spacer
(2) Install the idler gears to the idler gear support.
(3) Press-fit or expansion-fit the shaft into the support and
Bearing
secure with bolts and washers. Idler gear
(4) Install the shaft retainer to the idler gear support with
bolt and washer.
(5) Connect the idler shaft and retainer with bolt and
washer. Idler gear shaft
Shaft retainer
(6) Check the smooth rotation of idler gear.
Idler Gear - Install
3.2 Idler Gear Backlash - Measure
Hold a gear to fix the rotation. Apply a dial gauge plunger
tangentially on the pitch circle of the other gear, and mea- Hold an idler gear
sure the backlash.
If the backlash exceeds the limit, replace the gear with new
one.

0.12 to 0.22 mm 0.5 mm
Idler gear backlash
[0.0047 to 0.0087 in.] [0.020 in.]
Idler Gear Backlash - Measure

3.3 Front Gear Case - Assemble
(1) Install the snap ring, spacer and bearing to the oil-pump
Bearing Oil pump idle
idler gear. Spacer Shaft
Front
(2) Install the oil-pump idler gear to the front gear case.
gear case
(3) Press-fit or expansion-fit the oil-pump idler shaft into Oil pump idler gear
the front gear case and secure with bolts and washers. Snap ring
(4) Install the oil-pump-shaft retainer with O-ring to the Idler gear support
front gear case and tighten the bolt to connect with the Fixing nut
oil-pump idler shaft. Idler gear support
Oil pump idle

ࠉࠉࠉࠉshaft retainer
Front Gear Case - Assemble
8-22 99089-40100

Install the water pump and oil pump to the front gear case, and measure the backlash by either of the following methods : mea-
sure the gear backlash with a dial gauge applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure
the clearance between gears by inserting a feeler gauge between the engaging gear teeth. If the value exceeds the limit, replace
the gear with a new one.
Remove the water pump and oil pump after measuring the backlash.

0.10 to 0.28 mm 0.5 mm
Backlash between idler gear and water pump gear
[0.0039 to 0.0110 in.] [0.020 in.]
0.12 to 0.22 mm 0.5 mm
Backlash between water pump gear and oil pump idler gear
[0.0047 to 0.0087 in.] [0.020 in.]
0.12 to 0.22 mm 0.5 mm
Backlash between oil-pump idler gear and oil pump gear
[0.0047 to 0.0087 in.] [0.020 in.]
$
Crank gear
Damper
Idler gear
Idler gear
Backlash
0.10 to 0.28
[0.004 to 0.011]
Backlash
0.10 to 0.22
[0.004 to 0.009]
%
Water pump Backlash %
gear Backlash
0.10 to 0.22
0.10 to 0.28
[0.004 to 0.009]
[0.004 to 0.011]
Backlash
High-temperature 0.10 to 0.22 Water pump
[0.004 to 0.009]
system [0.004 to 0.009] Water pump gear
water pump
Low-temperature system
water pump
Oil pump Idler gear

Oil pump
Oil pump gear
Oil pump
A-A
99089-40100
8-23
3.5 Front Gear Case - Install

(1) Apply ThreeBond 1215 or equivalent o the end of oil
Front gear
pan gasket. ࠉࠉࠉcase Dowel pin
(2) Aligning with the dowel pins, install the gasket to the Idler gear
ࠉࠉSupport
crankcase.
Washer Crank
(3) Attach a lifting jig to the front gear case installed with case
idler gears, and install the front gear case aligning with
Oil pan
the dowel pins on crankcase. 57N・m
{5.8kgf・m}
(4) Tighten the front-gear case setting bolt with washer to Apply ThreeBond 1215
Front or equivalent to oil
the specified torque. gear case weight
pan gasket end.
(Including idler gear)
(5) Check the faces of crankcase, oil pan and front gear Approx. 115kg[254 lb.] Gasket
Front Gear Case - Install
case to be flush with each other.
3.6 Backlash Between Crank Gear and Idler Gear - Measure

Insert a feeler gauge between the idler gear and crank gear
to measure the back lash. If the backlash exceeds the limit,
replace the gear with new one.
Feeler gauge

Backlash between crank gear and 0.10 to 0.28 mm 0.5 mm
idler gear [0.0039 to 0.0110 in.] [0.020 in.]
Backlash Between Idler Gear and Crank Shaft Gear -

Measure
3.7 Oil Seal Retainer - Install
(1) Aligning with the dowel pins, install the gasket to the
Front gear case Dowel pin
front crankcase.
(2) Attach a lifting jig to the retainer, and install the
retainer aligning with the dowel pins. Washer
(3) Tighten the retainer bolts with washers. Nut
Oil seal retainer

weight:
Approx. 65 kg [143 lb.]
Oil seal retainer Gasket
Oil Seal Retainer - Install
8-24 99089-40100
3.8 Oil Seal - Install

Install the oil seal with the oil seal installer.
(1) Apply clean engine oil evenly to the oil seal lip, and
Oil seal retainer
attach to the oil seal retainer.
(2) Set the oil seal installer to the front end of crankshaft.
(3) Tighten the three wing nuts of oil seal installer evenly
by hand to insert the oil seal. Stop the tightening when
tip of installer contacts the clinger.
Note: When installing the oil seal, pay attention to the orien- Oil seal installer
tation of the oil seal and not to damage the oil seal. P/N: 41091-04900
Oil Seal - Install (1)
Oil seal retainer

Wing nut
22 ± 0.1mm [0.87 ± 0.004in.]
Apply clean
engine oil to
oil seal lip.
Oil seal
Slinger
Oil seal installer
Oil Seal - Install (2)
99089-40100
8-25
3.9 Damper - Install

(1) Install two guide stud bolts (M22 × 1.5, approx. 400
mm [15.75 in.] in length) to the crankshaft damper-set-
ting-thread holes in a horizontal position. Oil seal
(2) Hitch a belt sling to the damper and lift it. Aligning Retainer
with the crankshaft dowel pin, place the damper to be Dropout preventive
supported by the two guide stud bolts. stud bolt
(3) Aligning with the crankshaft dowel pin, place the
spacer to be supported by the two guide stud bolts. Front
(4) Hitch a belt sling to the damper and lift it. Aligning gear case
with the spacer dowel pin, place the damper to be sup-
Installing Position of the Damper Holding Stud Bolts.
ported by the two guide stud bolts.
(5) Check the damper position to be supported on the bolts
not to fall, then remove the belt sling.
Damper
Apply Moly LG Grease No. 2 (SUMICO) or equivalent
to the damper-setting bolt threads and bearing surface,
and tighten the bolt with washer to the specified torque.
Damper weight:
Max 290 kg
[639 lb.]
Damper - Install
Spacer
Spacer - Install
Damper
618N・m{63kgf・m}
[456 lbf・ft]
Apply Moly Grease
No.2 or equivalent
to threads and bearing
face.
Damper - Install
8-26 99089-40100
3.10 Thermo Label - Stick

Stick two thermo labels of 75 to 95°C [167 to 203°F] and
100 to 120°C [212 to 248°F] for the monitoring of the ࢧ࣮ࣔࣛ࣋ࣝࠉ㸺5E-75㸼
damper maximum temperature on the damper front face. 75 80 85 90 95
Measurement
Part name Part number
range
75 to 95°C
Thermo label 75 to 95 32522-04111
[167 to 203°F] ࢧ࣮ࣔࣛ࣋ࣝࠉ㸺5E-100㸼
100 to 120°C
Thermo label 100 to 120 32522-04211
[212 to 248°F] 100 105 110 115 120
Thermo Label - Stick

3.11 Damper Cover - Install
Rod
Damper cover
The silicone oil in the damper will be raised its temper-
Washer
ature and rapidly deteriorated, and it can results in a
serious accident by the functional decline of damper, if
the damper interferes with adjacent part.
Collar
Install the damper cover with the rods, collars, washers, nuts
Nut
and bolts paying attention not to interfere with the dumper.
Rod
Washer Bolt
Damper Cover - Install
99089-40100
8-27
4. Rear Mechanism - Assemble

4.1 Camshaft - Assemble
Assemble the camshaft referring to the procedure below when the camshaft is disassembled or replaced with a new one.
(1) Tap-in the dowel pins to the camshaft. Stake the ø16 mm dowel pin on the camshaft setting flange with punch to prevent it
from falling.
(2) Screw in the camshaft connecting stud bolts on the rear camshaft. Check the stud bolt length of nut side L.
(3) Tighten the camshaft connecting nut in the dry condition to the specified torque.
68.6 N·m {7.00 kgf·m} [50.597 lbf·ft]

Tightening torque of camshaft connecting nut 1CV-type injection pump ·New and Old cam spec.
(Dry condition without applying oil)
1CV type injection pump new type cam spec
Camshaft (front) ø8 mm [0.32in.] dowel pin Camshaft (rear) ø8 mm [0.32in.] dowel pin
ø8 mm [0.32in.] dowel pin
68.6 N·m {7.0 kgf·m} Camshaft Rear side camshaft,

[51 lbf·ft] connecting stud bolt camshaft gear
mounting stud bolt
Camshaft - Assemble
8-28 99089-40100
4.2 Camshaft - Install
Wire rope
Camshaft guide
Pay attention not to damage the cam lobes and jour- P/N: 41091-02900
nals on the camshaft, and camshaft bushings.
(1) Install the camshaft guide at the front end of camshaft.

(2) Apply an even coat of clean engine oil to the camshaft
journals and the camshaft guide.
(3) Lift the camshaft with sling and insert the camshaft into
Apply engine oil.
the camshaft bushing from the engine rear end.
(Insert from the engine rear end. )
(4) Install the camshaft to the position and remove the cam-
Camshaft - Install
shaft guide.
4.3 Idler Gear and Idler Shaft - Install

Place the right bank No.1 cylinder in the TDC condition to
install the idler gear and idler shaft.
(1) Install the idler shaft to the crank case with bolt and
washer.
(2) Hitch a sling to the rib hole in idler gear and lift the Idler shaft
gear.
(3) Adjust the idler gear to the matching mark of crank Thrust plate
gear, and install it to the idler shaft.
(4) Install the thrust plate to the idler gear, and tighten the
thrust plate setting bolts to the specified torque. 98 N·m
{10 kgf·m} Crank gear
[72 lbf·ft] Idler gear
Idler Gear and Idler Shaft - Install
4.4 Engine - Turning
Install two bolts at the crankshaft rear end to use as support-
ing pillars. Turn the crankshaft in the forward direction with
a bar to bring the No.1 cylinder at the TDC condition.
Bar
Bolt (M22×1.5)
(Engine rear end)

Engine - Turning
99089-40100
8-29
4.5 Timing Gear Train Matching Marks - Check

Ensure that the matching marks on the timing gears are
Camshaft gear Camshaft gear
aligned as shown in the illustration.
R R
L L
No.1 crank pin position
R
L
% %
%
%
R L
/ /
5 5
Idler gear R
L Idler gear
L
L Direction of L
R
rotation T
R
R
Crank gear
( Right-bank No.1 cylinder compression TDC

position seen from engine rear (
Timing Gear Train
4.6 Inspection before installing the timing gear case
When the timing gear is assembled after the disassembly,
install the camshaft gear before assembling to the timing
gear case, and check the items blow:
4.6.1 Camshaft Gear Backlash - Measure
Measure the gear backlash with a dial gauge applied to a
tooth flank on the pitch circle at a right angle to the tooth
axis, or measure the clearance between the engaging gear Camshaft
teeth of camshaft gear and idler gear by inserting a feeler gear
Idler gear
gauge. If the backlash exceeds the limit, replace the cam-
shaft gear or idler gear with a new one.
Camshaft Gear Backlash - Measure (1)
Measurement item Standard value Limit value Camshaft gear

Backlash between camshaft 0.12 to 0.22 mm 0.50 mm Idler gear
gear and idler gear [0.0047 to 0.0087 in.] [0.0197 in.]
Note: Remove the camshaft gear after the measurement to

install the timing gear case.
Camshaft Gear Backlash - Measure (2)
8-30 99089-40100
4.6.2 Idler Gear End Play - Measure

Measure the end play of the idler gear. If the value exceeds
the limit, replace the idler shaft, thrust plate or idler gear
with a new one.

New-type idler 0.2 to 0.6 mm
Idler gear end gear [0.008 to 0.024 in.] 1.0 mm Idler gear
play Old-type idler 0.2 to 0.4 mm [0.039 in.]
gear [0.008 to 0.016 in.]
Idler Gear End Play - Measure
99089-40100
8-31
4.7 Backlash Between Idler Gear and Crank Gear - Measure

Measure the gear backlash with a dial gauge applied to a
Idler gear
tooth flank on the pitch circle at a right angle to the tooth
axis, or measure the clearance between the engaging gear
teeth of idler gear and crank gear by inserting a feeler
gauge. If the backlash exceeds the limit, replace the idler
gear or crank gear with a new one.
Crank gear
Backlash between idler gear 0.10 to 0.24 mm 0.50 mm
and crank gear [0.0039 to 0.0094 in.] [0.0197 in.]
Backlash Between Idler Gear and Crank Gear -
Measure
4.8 Timing Gear Case - Install
(1) Check the dowel pin for wear.
Gasket
Replace the dowel pin if it is worn or the timing gear
case is replaced.
(2) Install the gasket to the timing gear case aligning with
the dowel pin. Cut the exploded gasket from the bottom 59N・m
{6.0kgf・m}
of timing gear case to be flush with the bottom face of [431 lbf・ft]
timing gear case. Timing Dowel pin
gear case
(3) Apply ThreeBond 1215 or equivalent o the end of cut Timing gear case
Weight: Approx. 130 kg
gasket. [287lb.]
(4) Install the lifting jig to the timing gear case, and lift 59N・m{6.0kgf・m}[431 lbf・ft] Dowel pin hole
Timing Gear Case - Install (1)
with a hoist.
(5) Install the timing gear case with gasket to the crankcase Gasket
and tighten the case setting bolts to the specified torque. Timing gear case Dowel pin
Dowel pin hole

Align.
Cut to be flush with the timing Oil pan

gear case bottom end face. Gasket
Apply ThreeBond 1215 or 59N・m{6kgf・m}
equivalent to the cut end. [43 lbf・ft]
Timing Gear Case - Install (2)
8-32 99089-40100
4.9 Camshaft Gear - Install

Place the right bank No.1 cylinder in the TDC condition to
install the camshaft gear.
(1) Install the camshaft end by aligning its hole with the
dowel pins on camshaft.
Camshaft gear
(2) Install the camshaft gear aligning with the matching 68.6 N·m mounting nut
mark on the idler gear and the dowel pin on camshaft {7.0 kgf·m}
[51 lbf·ft]
end.
(Dry)
(3) Tighten the camshaft gear setting nut in the dry condi-
Camshaft
tion to the specified torque.
Camshft end
Camshaft gear
Camshaft Gear - Install
(1CV-type injection pump, new-type cam spec.)
4.10 Backlash Between Camshaft Gear and Idler Gear - Measure
Measure the backlash by inserting a feeler gauge between
the engaging gear teeth of the camshaft gear and idler gear
Camshaft gear
after installing the camshaft gear. If the backlash exceeds
the limit, replace the camshaft gear or idler gear with a new
one.

Backlash between camshaft 0.1 to 0.24 mm 0.50 mm
gear and idler gear [0.004 to 0.0094 in.] [0.0197 in.]
Feeler gauge
Camshaft Gear Backlash - Measure

4.11 Camshaft Bearing and Camshaft Gear Cover - Install
(1) Install the camshaft cover with O-ring to the timing
Camshaft gear cover
gear case.
(2) Install the spacer to the shaft end.
(1CV type injection pump new type cam spec only)
Camshaft bearing
1CV type injection pump Spacer

new type cam only
Camshaft Gear Cover - Install
(3) Install the camshaft bearing with the installer to the
camshaft gear cover.
Installer
Camshaft Bearing - Install
99089-40100
8-33
4.12 Tachometer Shaft and Tachometer Installation Cover - Install

(1) Install the tachometer shaft to the camshaft end.
(2) Install the tachometer installation cover with the oil seal Camshaft bearing
and O-ring to the camshaft gear cover.
Shaft end
For tachometer
Shaft
Oil seal
O-ring
Tachometer installing cover
Tachometer Installation Cover - Install
4.13 Oil Seal and Oil Seal Case - Install
Oil Seal (Side Seal Type) - Install
Apply clean engine oil to the oil seal lip, and install the oil
seal with gasket to the timing gear case.
Note: Pay attention not to bend or damage the oil seal lip.
Oil seal
Oil Seal - Install
8-34 99089-40100
4.14 Flywheel - Install
340 350 0
Be careful not to drop or bump the flywheel. It will R1.R8
result in personnel injury as well as damage of the fly- Align the flywheel punch mark
"0" with crank shaft
wheel. No. 1,No. 8 crank pin, then
assemble.
(1) Check the mounting surfaces of flywheel and crank-

Then after the assembling,
punch "0" on the dowel pin. ࠉ
shaft to make sure that they are free from any foreign
material or damage.
(2) Attach sling to the flywheel.
Align the No.1 and No.8 pin of crankshaft and the
punch mark "0" on flywheel, and install the flywheel to Flywheel Installing Position
crankshaft.
(3) Apply Moly LG Grease No. 2 (SUMICO) or equivalent Apply Moly Grease
to the flywheel-setting bolt threads and bearing face, No. 2 or equivalent
and tighten the bolt with washer to the specified torque. to bearing face
618N・m{63kgf・m}
[456 lbf・ft]
Flywheel
Mounting bolt
618N・m
{63kgf・m}
[456 lbf・ft]
Fly wheel weight (including ring gear): Approx. 212 kg[467 lb.]
Flywheel - Install
(4) Install the pointer to the timing gear case with bolt and
washer.
Bolt, washer
Pointer
Pointer - Install
4.15 Flywheel Face and Radial Runouts - Measure
Measure the face and radial runouts of the flywheel.
If the value exceeds the limit significantly, check the assem-
bled condition such as a loose bolt or foreign material adhe-
sion on the mounting faces.
Dial gauge
Face runout (reference) 0.33 mm [0.0130 in.] or less
Radial runout (reference) 0.13 mm [0.0051 in.] or less
Flywheel Face and Radial Runouts - Measure
99089-40100
8-35
5. Cylinder Head and Valve Mechanism - Assemble

5.1 Tappet and Tappet Guide - Install
Tappet
(a) Be sure to install the tappet in the correct orienta-
tion. The camshaft will be damaged and result in a
Engine oil
serious damage of engine if the rotational direc- Apply
tions of the tappet roller and cam lobe are not in
the same direction.
Spring washer
(b) Check that the tappet shaft is not protruded from
the tappet guide face. If the tappet shaft is pro- Set screw
truded from the tappet guide face, the tappet

guide will be damaged. Tappet and Tappet Guide - Install
(1) Insert the tappet guide into the tappet guide hole in the
crankcase, and set the tappet guide with the set screw
and spring washer. Tappet
(2) Apply an even coat of clean engine oil to the tappet, Camshaft
tappet roller and bushing.
(3) Check that the tappet shaft is not protruded from the
guide face and the tappet orientation is correct, then
slowly insert the tappet until it is seat on the camshaft. Tappet proper Tappet improper
installing direction installing direction
Tappet Orientation
Tappet shaft
Tappet Guide face
Tappet Guide face

5.2 Bushings on Crankcase Upper Face - Install
Inlet port bushing

(a) Do not use the liquid gasket. Push rod
(b) Replace the bushings and seal rings to new ones hole bushing
when the cylinder head assembly is disassem-

Seal ring
bled. Do not re-use them.
(1) Wipe off dirt on the crankcase and cylinder liner upper
faces with waste cloth.
(2) Place four cooling-water-hole bushings, two push-rod- Cooling water port
bushing
hole bushings, one air-intake-hole bushing and one seal
Bushings and Seal Ring on Crankcase Upper Face -
ring to each cylinder.
Install
8-36 99089-40100
5.3 Copper Tube - Install

(1) Remove dirt on the copper-tube seat face in cylinder Cupper tube installer
head with waste cloth. P/N: 41091-02200
(2) Install the O-rings to the copper tube and apply grease
Cylinder head
to the O-ring.
O-ring (Apply grease.)
(3) Apply ThreeBond 1215 or equivalent o the bottom face
of copper tube. Cupper tube
(4) Insert the copper tube into the cylinder head. Use the
Apply ThreeBond 1215
copper tube installer and tap in the tube paying atten- or equivalent to
the copper tube
tion not to deform the tube. Stop the tapping when the
bottom face.
copper tube contacts the seat face in cylinder head.
Copper Tube - Install
(5) Apply an even coat of clean engine oil to the copper-
tube setting-nut threads. Tighten the nut to the specified Cupper tube
Torque wrench nut wrench
torque with the copper tube wrench. P/N: 41091-03700
Cylinder head
Cupper tube
nounting nut
Apply engine oil
to threads.
147 N·m {15 kgf·m}
[108.42 lbf·ft]
Cupper tube
Copper-Tube Setting Nut - Tighten

5.4 Valve Stem Seal - Install
Stem seal installer

P/N:41091-01600
(a) Do not apply oil or sealant t o the valve-guide fit-
ting face of stem seal.
Apply engine oil to the valve stem before installing
Stem
the stem seal in order to ensure the initial lubrica- seal
tion of stem seal lip. Valve
(b) Always replace the stem seal with a new one. guide
Use the stem seal installer to install the stem seal.

Lightly tap the stem seal installer right above the stem seal
Stem Seal Installing
to avoid deformation and to ensure even installation. Stop
the tapping when the bottom of stem seal rubber contacts
the valve guide.
99089-40100
8-37
5.5 Valve and Valve Spring - Install

(1) Apply an even coat of clean engine oil to the valve
Valve springࠉ
stem, and insert the valve into the valve guide.
Presser
(2) Install the valve rotator, valve spring and upper retainer P/N:41091-11400
on the valve guide. Install the valve cotter using a valve
spring compressor.
Intake port side
valve
Intake cam
side valve
Exhaust port side valve Exhaust port side valve

Valve Cotter and Valve Spring - Install (1)
Valve cotter Upper retainer
Valve
Spring
Valve guide
Valve rotator
Valve Cotter and Valve Spring - Install (2)

(3) Tap the top of valve stem lightly several times with a
soft hammer to make sure that the valve spring and
valve cotter are properly installed and seated firmly.
Valve Cotter Installation - Check
8-38 99089-40100
5.6 Valve Sinkage - Measure

Measure the valve sinkage.
If the value exceeds the limit, replace the valve or valve seat
Seat width
ring with a new one. Lap the valve and valve seat ring
whenever the valve or the valve seat ring is refaced or
replaced.
Valve seat angle

Valve margin
1.0 to 1.9 mm 2.9 mm
Inlet
[0.039 to 0.075 in.] [0.114 in.] Valve sinkage
Valve sinkage
1.0 to 1.9 mm 2.9 mm
Exhaust
[0.039 to 0.075 in.] [0.114 in.]
Valve Sinkage - Measure
5.7 Cylinder Head Assembly - Install
Install the covers to three cylinder-head-setting stud- Eye bolt

bolt threads when the cylinder head is placed on the Head mounting
crankcase. ࠉࠉࠉstud bolt
Cover
(1) Remove dirt on the cylinder-head bottom face with
waste cloth.
Cylinder head
(2) Attach two eye bolts to the cylinder head and lift it with ࠉࠉassembly
a hoist. Place the cylinder head on the crankcase upper
face.
Cylinder Head Assembly - Install
99089-40100
8-39
5.8 Cylinder Head Setting Nut - Install

Install the cylinder head setting nut with the head hydraulic
Head hydraulic jack Shaft
jack, hydraulic hand pump, hydraulic hose and shaft. P/N:41091-04000 P/N:41091-02600
Note: Before applying the hydraulic pressure to the head hy- Hydraulic hose
P/N:05312-02100
draulic jack, loosen the air vent plug of the jack and
Hydraulic hand pump
bleed air and oil from the jack, retract the jack, then P/N:41091-02001
Air vent plug

Cylinder Head Setting Nut - Install
(a) Apply the hydraulic pressure of six head jacks at a time, and install all the six cylinder head setting nuts at a
time. If the nut is installed one by one, the cylinder head or stud bolt will be damaged.
(b) Before the job, check the hydraulic hose for damage, and each part of the head hydraulic jack and hydraulic
(1) Applay Moly LG Grease No.2 (SUMIKO) or equiva-

lent to the cylinder-head setting-stud threads, and install
Cylinder head Apply MOLYLG
the nut to the cylinder head. Then tighten the nut to a mounting stud bolt Grease No 2
snug torque. (680,&2/8%5,&$17&2/7')
Apply moly LG RUHTXLYDOHQWWR
grease No.2 WKUHDGV
Cylinder head
Cylinder-Head Setting Nut - Tighten Snugly

(2) Install the foot piece and hydraulic jack of the head
hydraulic jack.
(3) Tighten fully the tension rod of head hydraulic jack.
Foot piece
Head Hydraulic Jack - Install
8-40 99089-40100
(4) Connect the hydraulic hose from the hydraulic hand

Hose
pump to hydraulic jack, and apply hydraulic pressure of (Elongation direction) P/N:
63.7MPa {650kgf/cm2} [9246 psi] to extend the stud Approx. 5 mm 05312-02100
bolt. [0.20 in.] Oil pressure
63.7 MPa
{650 kgf/cm2}
[9246 psi]
Do not extend the head hydraulic jack to exceed the Stroke
stroke limit (red line) on the periphery of tension rod. Limit line
(Red line)
splash when the head hydraulic jack is extended over
the limit line. This may cause personal injury. Apply Hydraulic Pressure to the Head Hydraulic Jack.
(5) Insert the shaft to the periphery hole of cylinder-head
setting nut, and snug tighten the nut to the cylinder
head. Remove the shaft, release the hydraulic pressure,
and remove the head hydraulic jack.
Shaft
P/N:41091-02600
Cylinder-Head Setting Nut - Tighten Snugly

5.9 Bridge - Install
(1) Apply clean engine oil to the top faces of bridge guide
and valve.
Exhaust port
(2) Install the bridge placing its screw end to the inlet/
Valve bridge
exhaust port side.
Hand tighten the setting screw and nut.
Note: For the proper tightening of setting screw and nut, re-
Apply engine oil
fer to "Valve Clearance - Inspect and Adjust" of "AS- to bridge guide
SEMBLY OF BASIC ENGINE". and valve
top end.
Bridge - Install
5.10 Clearance Between Valve Bridge and Valve Cotter - Inspect
Measure the clearance between the valve bridge and valve
cotter. If the clearance is 1 mm or more after adjusting the
front/rear valve height with the valve bridge adjusting
screw, replace the valve bridge with a new one.
Note: Note: For the adjusting procedures, refer to "Valve
Clearance - Inspect and Adjust" of "ENGINE BODY -
ASSEMBLE ".
99089-40100
8-41
5.11 Rocker Shaft Assembly and Push Rod - Install
Nut Rocker bracket setting bolt.

235N・m{24kgf・m}
Adjusting screw [174 lbf・ft]
(a) Swing the rocker arms to check the smooth move-
Snap ring Rocker arm
ment.
Contact piece Rocker shaft
(b) Place the contact piece center to align with the (Apply engine oil.) (Apply engine oil.)
bridge top center, and hand tighten the rocker- Snap ring Rocker bracket
bracket setting bolt. Thrust plate
O-ring
(1) Apply clean engine oil to the push rod top/bottom Knock pin
faces, and install the push rod. Push rod
(2) Install the rocker shaft to the rocker shaft bracket align- (Apply oil to top and bottom end.)
Rocker Shaft Assembly and Push Rod - Install (1)
ing the oil holes. Tighten the set screw and nut to the
specified torque.
Nut 29.4N・m
(3) Apply clean engine oil to the rocker shaft and install the {3.0kgf・m}
Set screw [22 lbf・ft]
rocker arm.
57.8N・m
(4) Install the thrust plate and snap ring. {5.9kgf・m}
Rocker shaft [42 lbf・ft]
(5) Apply clean engine oil to the contact piece, and install
it to the adjusting screw with the snap ring. Rocker bracket
(6) Install the adjusting nut to the rocker arm and finger
tighten the nut. Knock pin
Note: For the proper tightening of adjusting screw and nut, Cylinder head O-ring
refer to "Valve Clearance - Inspect and Adjust" of Rocker Shaft Assembly and Push Rod - Install (2)
"ASSEMBLY OF BASIC ENGINE".
(7) Check the O-ring installed in the oil hole (dowel pin) on
the rocker-bracket installing face, then install the
bracket.
to the rocker-bracket setting-bolt threads and bearing
face, and tighten the bolt to the specified torque.
8-42 99089-40100
5.12 Both inlet and both exhaust valve heights by valve bridge - Adjust
If the clearance between the valve bridge and valve cotter is below the limit, the valve cotter may be displaced by
interfering. If the clearance is below the limit after adjusting the front/rear valve height with the valve bridge adjust-
ing screw, replace the most worn part among valve, valve cotter, upper retainer or valve bridge with a new one.

Valve bridge and 2.0 mm 1.0 mm
valve cotter clearance [0.079 in.] or more [0.039 in.] or more
Adjust the valve bridge screw to equalize the front/rear

valve heights before measuring the valve clearance. Valve clearance
Valve bridge
A clearance is made between the valve cotter and valve
bridge when the valve seat or other part is worn and the Valve cotter
heights of front/rear valves are not the same. This results in

an improper valve clearance measurement.
valve bridge and
valve cotter
Valve
Clearance Between Valve Bridge and Valve Cotter

(1) loosen the lock nut of valve-bridge adjusting screw, and
turn back the adjusting screw.
(2) Press the rocker arm by finger and slowly tighten the 10°further
tightening Adjusting
adjusting screw.
screw
(3) Turn the adjusting screw by approx. 10°when the tip of
Lock nut
adjusting screw contacts the valve-stem top face, then
Valve
fix the screw with the nut. Rocker arm Bridge
Valve stem
Front/rear Valve Height Adjustment By Valve Bridge
99089-40100
8-43
5.13 Valve Clearance - Check and Adjust

5.13.1 Compression TDC - Check
Knob
Mounting screw
Place the turning gear in the released position when-
ever start the engine.
Rocker cover
(1) Remove the lock pin of turning gear. And push the han-
dle to the arrow direction to place the turning gear in
the "Engaged" position. Rocker cover installation Rocker cover
Screw tightening torque
(2) Turn the turning gear shaft with a socket and ratchet 18 ± 2 N・m {1.8 ± 0.2 kgf・m} Gasket
[13±1lbf・ft]
wrench when the gear is in the "Engaged" condition to
Rocker Cover - Remove
turn the crankshaft. Move the ratchet handle from lower
to upper position to turn the crankshaft in the forward
direction (counter-clockwise seen from the flywheel Ratchet handle
end).
Socket
Handle
Turning
Gear shaft Engaged
Released
Released (
Fixing bolt starting)
(starting)
Turning Gear - Operate
(3) Check the inlet and exhaust valve clearances of the cyl-
Cylinder in TDP condition
inder referring to the alignment of flywheel punch mark (Crank angle)
and pointer which shows the TDC of two cylinders.
The cylinder which has valve clearances is in the com-
pression TDC condition. O
R1.R6
(Example) When the pointer is aligned with "R1·R6" S12U
S12U Clearance
damper punch mark, either No. R1 or No. R6 cylinder
in the right bank is at the compression TDC. Pointer
O
R1. R8
S16U Fly wheel punch line

Compression Top Dead Center - Check
8-44 99089-40100
5.13.2 Valve Clearance - Inspect

Check the valve clearance after adjusting the front and rear
valve height of valve bridge.
(1) Inspection and adjustment sequence of valve clearance.
Inspect and adjust the valve clearances according to the
engine firing order and at the compression TDC of each
cylinder.
Measure-
Cylinder Number
ment item
R1-L1-R6-L6-R2-L2-R4-L4-R8-L8-R3-L3-R7-
Firing order
L7-R5-L5
(2) Insert the feeler gauge which has the same thickness to
the specified valve clearance between the rocker arm
and bridge cap of the appropriate cylinder.
Feeler
gauge
Standard
Measurement item
value
0.6 mm
Inlet valve
[0.024 in.]
Valve clearance
0.8 mm
Exhaust valve
[0.032 in.]
(3) Move the feeler gauge. The valve clearance is proper

when the movement feels mild restriction. Adjust the Valve Clearance - Inspect
valve clearance referring to the procedure in "Valve

Clearance - Adjust" when the feeler gauge can not be
inserted or the restriction is too tight.
5.13.3 Valve Clearance - Adjust
(1) Loosen the lock nut of rocker-arm adjusting screw.
(2) Adjust the screw to feel a mild restriction of the feeler Adjusting screw
gauge. Lock nut
(3) Tighten the lock nut to fix the adjusting screw when the
clearance becomes the standard value.
Valve Clearance - Adjust

5.13.4 Rocker Room - Inspect
Rocker arm Piece
Adjusting screw
Inspection items Inspection item
Rocker shaft
Looseness
bracket Valve bridge
Rocker arm and
Wear, oil hole clogging and looseness of piece
valve bridge
Adjusting screw Damage on threads
Cylinder Head Crack, damage, carbon deposit
Rocker shaft bracket

Rocker Room - Inspect
99089-40100
8-45
5.13.5 Turning Gear - Release
Ratchet handle
Place the turning gear in the released position when- Socket

ever start the engine. Starting with the turning gear in
an engaged condition will result in a serious accident
Handle
to break the ring gear.
Turning
Be sure to return the turning gear handle to the released Gear shaft Engaged
position and insert the lock pin after finishing the valve Released
Released (
(starting)
clearance adjustment.
8-46 99089-40100
5.14 Fuel Injection Timing - Inspect and Adjust

5.14.1 Fuel Injection Timing and the Position of Cau-
tion Plate VALVE CLEARANCE㸦COLD㸧
ࣂࣝࣈࠉࢡࣜ࢔ࣛࣥࢫࠉ㸦࢚ࣥࢪࣥ෭᫬㸧
The fuel injection timing differs according to the output INLET 0.6mm EXHAUST0.8mm
࢖ࣥࣞࢵࢺ ࢚࢟ࢰ࣮ࢫࢺ
power, engine speed and specification. Confirm the fuel FIRING ORDER ╔ࠉⅆࠉ㡰ࠉᗎ
R1-L1-R6-L6-R2-L2-R4-L4
-R8-L8-R3-L3-R7-L7-R5-L5
injection timing of each engine with the caution plate FUEL INJECTION TIMING
⇞ ᩱ ᄇ ᑕ ᫬ ᮇ BTDC
attached on the No. R1 rocker cover.

For the adjusting procedures, refer to "Valve Clearance -
Inspect and Adjust" of "ENGINE BODY - ASSEMBLE ".
Caution Plate Position

5.14.3 Injection Timing - Check
(1) Remove the cam room cover of the appropriate injec-
tion pump.
(2) Turn back the crankshaft to approx. 30°before compres-
sion TDC of the cylinder.
(3) See the inspection window of injection pump, and turn
slowly the crankshaft in the forward direction. Matching mark
(4) Stop the turning when the matching marks are aligned
in the plunger upward movement, and read the flywheel
stamp line.
Matching Marks on the Fuel Injection Pump
(5) This is the fuel injection starting position.
Flywheel Punch Mark and Matching Mark

(In the Case of Fuel Injection Timing 22°BTDC)
99089-40100
8-47
5.14.4 Injection Timing - Adjust

Adjust the fuel injection timing by adjusting the shims
installed below the fuel-injection-pump setting flange.
The shim thickness rage is from 0.5 mm [0.020 in.] to 2.0 mm [0.079 in.] for the adjustment. The fuel injection pump
will be damaged if the shim thickness is out of the shim thickness range.
(1) Check the shim thickness installed in the fuel injection
pump before adjustment. And consider the necessity of
injection timing adjustment.
Note: Store the shims as a set for each cylinder.
(2) Close the fuel in/out valves to shut off the fuel supply.
Note: Drain the fuel in the fuel pipe by air bleed valve if the
fuel is remained.
(3) Remove all the pipes connected to the fuel injection
pump.
(4) Loosen all the bolts fixing the fuel injection pump, and
Injection pump
raise the pump to make a clearance at the dowel pin. Fixing bolt
167±17N・m
(5) Adjust the shim thickness for the proper injection tim- {16.7±1.7kgf・m}
ing. >±12 lbt·ft]ࠉࠉ
Note:(a) Increase the shim thickness to retard the injection

timing, or reduce to advance.
(b) Code marks are stamped on the shims for the indi-
Shim
cation of thickness.
Mark punching
position
Injection Timing - Adjust
Fuel injection timing shift

Shim thick-
Ref. No.
ness
amount BTDC ATDC
(crank angle) Advanced Retarded
0.2mm angle angle
1 0.72°
[0.008 in.]
Shim thickness Shim thickness
0.3mm reduce increase
2 1.08°
[0.012 in.]
Injection TDC (Crank angle)
0.5mm
3 1.80° timing (TDC)
[0.020 in.]
Change of Injection Timing
8-48 99089-40100
(6) Tighten the fuel injection setting bolts to the specified

torque, and open the cam chamber cover of each cylin-
der.
(7) Turn the crankshaft and verify that the fuel-injection-
pump tappet roller contacts camshaft fuel cam lobe
without clearance.
Note: The change of fuel injection timing must be within
2°of crank angle when the timing is adjusted by the
sims.
If the adjustment of 2°or more of crank angle is re-
quired, replace the cam gear. Clearance
is not allowed.
Clearance Between Cam and Tappet - Inspect

(8) Install the pipes connected to the fuel injection pump
after adjusting the fuel injection timing.
Install the cam room cover.
(9) Check the fuel leak and engine oil leak after supplying
the fuel. Replace the caution plate on the rocker cover
to the new one showing the stamp of changed injection
timing.
99089-40100
8-49
5.15 Valve Timing - Inspect

The timing check is not necessary with the correct combination of matching marks. However, check the valve timing to ensure
the correct assembly.
(1) Insert a feeler gauge of 2 mm [0.08 in.] thick into the intake and exhaust valves in No. 1 cylinder to adjust the valve clear-
ance of 2 mm [0.08 in.].
(2) Place the thinnest 0.05 mm [0.0197 in.] in thick feeler gauge between the valve bridge and contact piece. Turn the crank-
shaft and measure the timings of grip (valve opening timing) and release (valve closing timing) of feller gauge. These are
the timings when the valve clearance is 2 mm [0.08 in.]. Check the value to be within the allowance of the shown nominal
values.

Valve timing of inlet and exhaust valves ±4°or less to the nominal value
Note: The valve timing varies with the cam gear specification as it varies with the injection timing.
The engine serial numbers below are reference only. The specification varies with the engine.
In the Case of Standard Fuel Injection Timing of
16°BTDC, 1CV-Type Injection Pump and New Cam- TDC
Intake valve open
Exhaust valve close 25°
shaft Spec.
15°
10080 and After
84° 103°
Intake cam
Max lift
Exhaust cam
96° Max lift
77°
Exhaust valve open 41° 13°
Intake valve close
Direction of rotation BDC
When valve clearance is 2mm [0.08 in.]
Valve timing diagram
TDC
14°
Fuel injection start
Exhaust valve close 53° 60°
84° Intake valve open
Intake cam
Max lift 103°
Exhaust valve Exhaust cam
open Max lift
96°
77°
79°
Direction of 48° Intake valve close
rotation BDC
When valve clearance is 0mm [0.00 in.]
Valve timing diagram
8-50 99089-40100
5.16 Nozzle Assembly - Install

Nozzle retainer nut
Nozzle reatiner Nozzle holder
196N・m
Check the position of fuel-inlet-connector installing Washer {20kgf・m} O-ring
(Place the
[145 lbf・ft] (Apply grease.)
hole of nozzle holder to be centered, or the threads sphere face
bottom.)
will be damaged by installing the inlet connector. Fuel inlet
Nozzle reatiner
connector
88 to 98N・m
(1) Remove the fuel inlet connector from fuel injection {9 to 10 kgf・m}
[65 to 72 lbf・ft]
nozzle assembly. O-ring
(2) Install O-rings on the nozzle holder and fuel inlet con- Nozzle retainer stud bolt (Apply grease.)
(Apply oil to threads.)
nector. Apply grease to the O-ring sliding surfaces.
(3) Check the copper tube and its setting nut in the cylinder
Nozzle Assembly - Install
head to be installed properly.
(4) Install the nozzle holder into the cylinder head adjust-
ing its orientation of inlet-connector installing hole.
(5) Tighten the fuel inlet connector to the specified torque.
5.17 Rocker Cover - Install

(1) Install the rocker cover after the valve clearance adjust-
Knob
ment.
Note: Wipe off engine oil on rocker cover gasket and sealing Mounting screw
face if smeared.
(2) Adjust the rocker cover position to avoid the slanted Rocker cover
position of setting screw.
(3) Hand tighten the setting screw knob, then tighten to the
specified torque with a wrench. Rocker cover installation Rocker cover
18 ± 2 N・m {1.8 ± 0.2 kgf・m} Gasket
[13±1lbf・ft]
Rocker Cover - Install
99089-40100
8-51
1. Environmental Condition to Disassemble and Assemble the Fuel System....... 9-3
2. Fuel System - Remove and Inspect ....................................................................... 9-4
2.1 Fuel Injection Pump and Fuel Pipe - Remove and Inspect....................................................... 9-4
2.2 Fuel Filter, Fuel Pump and Fuel Pipe - Remove and Inspect ................................................... 9-6
2.3 Governor Control Link - Remove and Inspect .......................................................................... 9-7
2.4 Fuel Control Link - Remove and Inspect .................................................................................. 9-8
2.5 Fuel Splash Protection Cover - Remove and Inspect............................................................... 9-9
2.6 Stop System - Remove and Inspect ....................................................................................... 9-10
3. Fuel System - Disassemble, Inspect, and Assemble ......................................... 9-11
3.1 Fuel Filter (Wire Mesh Element) - Disassemble, Inspect and Assemble................................ 9-11
3.2 Fuel Filter and Accumulator - Disassemble and Inspect ........................................................ 9-14
3.3 Injection Nozzle - Disassemble and Inspect ........................................................................... 9-19
3.4 Governor Drive - Disassemble, Inspect and Assemble .......................................................... 9-23
3.5 Fuel Filter - Disassemble, Inspect and Assemble................................................................... 9-27
3.6 Fuel oil return relief valve (1CV-type injection pump only.) .................................................... 9-30
4. Fuel System - Install .............................................................................................. 9-31
4.1 Fuel Injection Pump and Fuel Pipe - Install ............................................................................ 9-31
4.2 Fuel Filter, Fuel Pump and Fuel Pipe - Install......................................................................... 9-32
4.3 Governor Control Link - Install ................................................................................................ 9-33
4.4 Fuel Control Link - Install ........................................................................................................ 9-34
4.5 Control shaft assembling procedure ....................................................................................... 9-35
4.6 Stop System - Install............................................................................................................... 9-37
99089-40100
9-1
1. Environmental Condition to Disassemble and Assemble the Fuel System

To keep the cleanliness of the engine and parts in installing,
removing, inspection and repair works of the fuel system of
this engine, obey the instructions below:
Clean the engine before the work.
Drying and cleaning with compressed air must be
done before removing the fuel system, as the
dust may enter into the injection pipe.
Seal the openings of fuel system parts with plugs
or others immediately after the removal to avoid
entering of foreign substances.
The assembling job must be done on a clean
stainless-steel-top work table.
Use clean tools, and clean the tools after the job.
Install a filter to the air inlet fan if installed on the
working room. Do not use fan in the working
room.
The worker must not wear fuzzy clothes, must
wear clean clothes and must not use hand cream
or others. Wear rubber gloves for precision-part
work if needed.
99089-40100
9-3
2. Fuel System - Remove and Inspect
(a) Make sure that there is no flame around the area before handling fuel system.
(b) Before disassembling and inspection, drain fuel in the engine, pay attention not to scatter fuel remaining in the
engine, and immediately wipe off fuel if spilt.
2.1 Fuel Injection Pump and Fuel Pipe - Remove and Inspect
R.H.
Replace
3 6
Replace Fuel 7
2 5 filter
1 4
13
8
12 12
CONTROL LINK BEARING 12 12
14 Replace
13
13
13 Replace FUEL
13 MAIN PIPE
15 11
Replace 12
13 11 CONTROL
LINK BEARING
Replace Replace
TIMING GEAR CASE
9
9
11 9
9 9
Replace
10
Fuel Injection Pump and Fuel Pipe - Remove and Inspect (Right Side)
Removal sequence
1 Fuel leak-off pipe, Clip, Bolt, Nut, Washer, Protect rubber 9 Accumulator, Connector, Bracket, U-bolt, Bolt, Nut,
2 Fuel leak-off pipe, Clip, Bolt, Nut, Washer, Protect rubber Washer, protect rubber
3 Fuel leak-off pipe, Clip, Bolt, Nut, Washer, Protect rubber 10 Relief valve, Bolt, Washer, O-ring
4 Fuel leak-off pipe, Stay, Clamp, Bolt, Washer 11 Over-flow pipe, Elbow, Clamp, Bolt, Washer,
5 Fuel leak-off pipe, Stay, Clamp, Bolt, Washer Protect rubber
6 Fuel leak-off pipe, Stay, Clamp, Bolt, Washer 12 Over-flow pipe, Elbow, Bracket, Clamp, Bolt, Washer
7 Fuel leak-off pipe, Clamp, Seat, Bolt, Nut, Washer, protect 13 Over-flow pipe, Connector, Stay, Clamp, Bolt, Nut, Washer
rubber 14 Valve, O-ring, Hose, Hose clamp
8 Fuel leak-off pipe, Clamp, Seat, Bolt, Nut, Washer, 15 Fuel main pipe, Bolt, Washer
Protect rubber
9-4 99089-40100
L.H.
17
Replace
16
15
14 6
14
5 3 Fuel
17
filter
13
4 2
Replace 10 10 7
11 1
12
CYLINDER
HEAD
A 7 7
10 B
18
20 8
Replace
21 18 Replace 9
22
20
19
Replace Replace
19 9
Replace
21
A
B
23
Fuel Injection Pump and Fuel Pipe - Remove and Inspect (Left Side)
Removal sequence
1 Fuel leak-off pipe, Clip, Bolt, Nut, Washer, Protect rubber 13 T-joint
2 Fuel leak-off pipe, Clip, Bolt, Nut, Washer, Protect rubber 14 Fuel leak-off pipe, Spacer
3 Fuel leak-off pipe, Clip, Bolt, Nut, Washer, Protect rubber 15 Instrument Pipe
4 Fuel leak-off pipe, Stay, Clamp, Bolt, Washer 16 Instrument Pipe
5 Fuel leak-off pipe, Stay, Clamp, Bolt, Washer 17 Fuel leak-off pipe
6 Fuel leak-off pipe, Stay, Clamp, Bolt, Washer 18 Valve, O-ring, Hose, Hose clamp
7 Fuel leak-off pipe, T-joint, 19 Fuel main pipe, Bolt, Washer
8 Check valve 20 Injection pipe, Connector, Snap ring, O-ring
9 Fuel leak-off pipe, Clamp, Bolt, Washer 21 Oil pipe, Union bolt, Sealing washer, Connector
10 Fuel leak-off pipe, Spacer 22 Bolt, Washer
11 Fuel leak-off pipe, Spacer 23 Fuel injection pump
12 Fuel leak-off pipe
Note: The part 21 is in the oil system.
99089-40100
9-5
2.2 Fuel Filter, Fuel Pump and Fuel Pipe - Remove and Inspect
Changeover-type (cartridge-type) oil filter spec.
Right injection pump
Replace: Protect rubber

3
3 Replace
1 Replace: Protect rubber
3
Replace: Protect rubber Timing gear case
2 2
Air duct
Replace
5
Left injection 5
pump
5
1
Replace: Protect
rubber Fill nitrogen gas, replace

6
6
Control link A
Bearing
7
7
3 7
6
Replace: Protect rubber 6

7
7
4
Replace
4
Fuel pump
Fuel Filter, Fuel Pump and Fuel Pipe - Remove and Inspect
(Changeover type - cartridge type - oil filter spec.)
Removal sequence
1 Fuel pipe, Clamp assembly 5 Fuel pipe, union bolt, Bolt, Washer, Sealing washer,
2 Fuel pipe, Clamp, T-joint Clamp assembly
3 Fuel pipe, Clamp assembly, Union bolt, Bolt, Nut, Washer, 6 Fuel filter, Accumulator, Connector, Bolt, Nut, Washer
Sealing washer 7 Bracket, Cup, Bolt, Nut, Washer
4 Fuel pipe, Union bolt, Sealing washer, Clamp
9-6 99089-40100
2.3 Governor Control Link - Remove and Inspect
3
Fatigue, wear
Align the matching marks to

ensure the assembling condition 4
before disassembling.
1
2
1
1
4
Adjust the distance between

ball joints to the value recorded at
disassembly an install the ball joints in
the same direction as that before
disassembly by aligning matchmarks.
Crankcase
Timing
gear case
Governor Control Link - Remove and Inspect

Removal sequence
1 Rod, ball joint, Nut, Washer 4 Lever, Set screw, Nut
2 Governor lever, Bolt, Washer 5 Oil pipe, Connector, Elbow
3 Lever, Spring, Snap ring
Note:(a) Record the ball joint length before disassembling the ball joint and rod. Make marks to show the ball joint assembled
direction to ensure the correct reassembling.
(b) Make marks on serration before disassemble the lever and shaft jointed at the serration to ensure the correct reassem-
bling.
(c) Refer to "LUBRICATION SYSTEM" for the parts in ---.
99089-40100
9-7
2.4 Fuel Control Link - Remove and Inspect
6
4
7
2
4
1 2
2 Fatigue,
1 wear 11
6 Wear, 11
7
1 damage
5 8 7
6 5 7
8 Replace
9
9 8
Mark the matching marks
3 10 on serrations.
11
11 9 7
12 Replace
8
13 8
10
10
9 7
Record the ball joit length

before disassembling
Mark the assembling direction
to the ball joint
Fuel Control Link - Remove and Inspect

Removal sequence
1 Control shaft lever, Set screw, Nut, Bolt, Washer 7 Control shaft, Bolt, Washer
2 Lever, Lever pin, Return spring, Snap ring, Nut 8 Lever, Oil seal, Nut, Washer
3 Bearing, Bolt, Washer 9 Ball joint, Rod, Nut, Washer
4 Bearing, Bolt, Washer, Snap ring 10 Lever, Bolt, Washer
5 Collar, Set screw, Nut 11 Retainer, Bushing, Snap ring, Bolt, Washer
6 Control shaft 12 Retainer, Bushing, Bolt, Washer
13 Control shaft
Note:(a) Record the ball joint length before disassembling the ball joint and rod. Make marks to show the ball joint assembled
direction to ensure the correct reassembling.
(b) Make marks on serration before disassemble the lever and shaft jointed at the serration to ensure the correct reassem-
bling.
9-8 99089-40100
2.5 Fuel Splash Protection Cover - Remove and Inspect
Fuel Splash Protection Cover - Remove and Inspect
99089-40100
9-9
2.6 Stop System - Remove and Inspect
1
7
7
1
6
3
6
5
5
5
2
Fatigue, wear
Stop System - Remove and Inspect

Removal sequence
1 Boss, Stay, Bolt, Washer 6 Bracket, Ball catcher, Bolt, Washer, Screw
2 Spring guide, Boss, Spring, Stopper 7 Lever, Bracket, Bolt, Nut
3 Air cylinder, Filter, Flexible Pipe, Elbow, Connector 8 Lever, Bolt, Washer
4 Stay, bolt, Washer
5 Hand lever, Clip, Return spring, Shaft valve spring, Bearing,
Bolt, Nut, Washer
Note: Mark the bolt 7 position to clarify the bolt 7 position before disassemble the bolt 7 to ensure the correct reassembling.
9-10 99089-40100
3. Fuel System - Disassemble, Inspect, and Assemble

3.1 Fuel Filter (Wire Mesh Element) - Disassemble, Inspect and Assemble
(a) Make sure that there is no flame around the area before handling fuel.
(b) Wipe off any spilled fuel. This can cause a fire.
(c) Prepare drip pan to avoid fuel spattering when disassemble and inspect.
3.1.1 Fuel Filter (Wire Mesh Element) - Disassemble
Replace
7
Replace
5
9
2
Crack, damage on threads

2
8
Turning
6 5
Replace
Replace
3
1
4 Cleaning
3 4 Water drain
Replace
Fuel Filter (Wire Mesh Element) - Disassemble

1 Drain plug, Sealing washer 5 Handle, Snap ring, Washer
2 Flange, Filter case, Packing, Bolt, Washer 6 Rod, O-ring
3 Element, Nut, Washer 7 Air vent plug, Gasket
4 Plate assembly, Collar, O-ring 8 Cover, Bolt, Washer
9 Bracket
99089-40100
9-11
3.1.2 Fuel Filter (Wire Mesh Element) - Inspect

(1) Fuel Filter (Wire Mesh Element) - Clean
Clean the element in fuel filter by turning the handle of filter
(wire mesh element) in the arrow (clockwise) direction 4 to
5 rounds.
Fuel Filter (Wire Mesh Element) - Clean

(2) Fuel Filter (Wire Mesh Element) - Drain Water
(a)Close the supply valve to engine.
(b)Prepare a drip pan and place it below the fuel filter
(wire mesh element).
(c)Turn the handle on the filter (wire mesh element) and
remove adhesives on the element.
(d)remove the drain plug, and discahrge the sediments in
the filter.
(e)Install the drain plug.
Drain plug
(f)Bleed air from the fuel system.
Fuel Filter (Wire Mesh Element) - Drain Water
(3) Fuel Filter (Wire Mesh Element) - Clean Inside
Check the filter case, drain plug screw and sealing washer for damage. Replace with a new one if damaged.
(a)Close the supply valve to engine.
Mounting bolt Wire element
(b)Prepare a drip pan and place it below the fuel filter
(wire mesh element).
(c)Remove the drain plug and sealing washer and drain
fuel.
(d)Remove the setting bolt on the filter and remove the
filter case. filter case
(e)Clean impurities around the wire mesh element with a
soft brush or others by applying the fuel. Sealing washer
(f)Clean the inside of the filter case. Drain plug
Fuel Filter (Wire Mesh Element) - Clean Inside
(g)Reassemble the drain plug, sealing washer and filter
case.
(h)Bleed air from the fuel system.
9-12 99089-40100
3.1.3 Fuel Filter (Wire Mesh Element) - Assemble and Inspect
19 N・m {2.0 kgf・m}

[14 lbf・ft]
Fuel Filter (Wire Mesh Element) - Assemble and Inspect

Note: Be sure to check the fuel inlet and outlet when assembling to the engine.
(a) After the installation bleed air from the fuel filter (wire mesh element).
(b) Start the engine to check fuel leak.
99089-40100
9-13
3.2 Fuel Filter and Accumulator - Disassemble and Inspect
(a) Prepare drip pan to avoid fuel spattering when disassemble and inspect.
(b) Make sure that there is no flame around the area before handling fuel.
(c) Wipe off any spilled fuel. This can cause a fire.
Changeover-type fuel filter (cartridge-type)
1 Crack, damage on threads
Fill nitrogen gas, replace Replace
8
10 9
Crack, damage on threads
7 Replace
9
6
5
5
3
4
Replace
2
Changeover-Type Fuel Filter (Cartridge-Type) - Disassemble and Inspect

1 Accumulator, Connector 6 Cover, Gasket
2 Filter cartridge 7 Changeover cock, O-ring
3 Spring pin 8 Air vent plug, Sealing washer
4 Handle 9 Plug
5 Name plate, Bolt, Washer 10 Bracket
Note: Replace the filter cartridge fit to the fuel.
9-14 99089-40100
3.2.1 Fuel Filter - Inspect and Replace

(1) Accumulator Inside Pressure - Inspect and Adjust
Remove the accumulator from the filter bracket, then mea-
sure the inside pressure. If the pressure is out of the stan-
dard, charge gas into the accumulator to adjust the inside
pressure.
Replace the accumulator with a new one if its pressure is out
of the standard value after gas charging.
(a)Check the connector between the accumulator and
bracket for such damages as crack.
(b)Replace the accumulate with a new on every 8 years
even if the pressure is within the standard value.
Note: Refer to the appendix 1 "Gas Charging Procedure" for
the accumulator gas charging.
Measurement item Nominal value Standard value

Accumulator inside
0.35 MPa 0.33 to 0.35 MPa
pressure (at an ambient
{3.57kgf/cm2} {3.37 to 3.57kgf/cm2}
temperature of 20°C
[50.76 psi] [47.86 to 50.76 psi]
[68°F])
99089-40100
9-15
(2) Changeover-Type Fuel Filter (Cartridge-Type) - Replace
(a) The fuel filter (cartridge type) element is a paper element which must not be reused by washing.
(b) Installation of the fuel filter cartridge must conducted by hand. Pay attention not to dent or scar the cartridge
face. Do not use a filter wrench to install.
(c) If the air bleed plug, threads of bracket or sealing washer is damaged, replace with a new one.
When the engine is stopped.

Normal position Left side replacing
(a)Close the fuel supply valve to engine. Right side replacing position
position (Only right-side
(b)Clear the fuel filter and its surroundings. n
pe
OPER ATION
N o r ma l L-
CL fuel filter allows
(Only left-side ef
to
gh
ts
top R-
OP SE
O
EN :
fuel flow.)
(c)Prepare a drip pan and place it below the fuel filter.
L
Ri
CL EN:
:R
fuel folter allows
Le
E:
ft
P
OS
ig
st en
L-O
ࠉ
ht
op
op
R-
fuel flow.)
(d)Place the fuel-filter changeover handle to L-CLOSE, ࠉ
ge
L-AI R PU
RGE: Right side air pur
N: L ef t o pen
R-OPEN: Right open

R-OPEN position.
RG E : L e f t si de
L -OPE
IR PU
(e)Remove the left two fuel filters with a filter wrench.
a ir p
R-A
ge ur
(f)Repair new fuel filters and apply clean fuel to the pack-
ing.
Right side air bleed position Left side air bleed psition
(g)Install the fuel filter on the bracket. Tighten the filter 3/
Fuel-Filter Changeover Handle
4 to 1 circle by hand after the filter contacts the
bracket. Left air vent plug, Right air vent plug,
(h)Place the fuel-filter changeover handle to L-OPEN, R- sealing washer sealing washer
CLOSE position and replace the right two filters in the

Bracket Changeover
same procedure as (e) to (g). handle
(i)After replacing the fuel filter, open the fuel supply Apply clean fuel
to the packing
valve to engine, and bleed air from the fuel system.
(j)Start the engine and idle for a few minutes.
(k)Check fuel leak from the fuel filter. If a leak if found, Right fuel
Left fuel
disassemble the filter to check flaw on the packing and filter filter
others, then reassemble the filter. Fuel Filter (Cartridge Type) - Replace
9-16 99089-40100
When the engine is running
Bring the engine to a no-load low-idling operation before replacing the fuel filter while the engine is running. The
replacement of filter in a high-speed running may results in a fuel leak at the changeover handle.
(a)Clear the fuel filter and its surroundings.
Normal position Left side replacing
(b)Prepare a drip pan and place it below the fuel filter. Right side replacing position
position (Only right-side
(c)Place the fuel filter handle to L-CLOSE, R-OPEN pe
n
OPER ATION
N o r ma l L-
CL fuel filter allows
(Only left-side ef
to
gh
ts
top R-
OP SE
O
EN :
fuel flow.)
position.
L
Ri
CL EN:
:R
fuel folter allows
Le
E:
ft
P
OS
ig
st en
L-O
ࠉ
ht
op
op
R-
fuel flow.)
(d)Remove the left two fuel filters with a filter wrench. ࠉ
ge
L-AI R PU
N: L ef t o pen
R-OPEN: Right open

(e)Repair new fuel filters and apply clean fuel to the
L -OPE
IR PU
packing.
a ir p
R-A
ge ur
(f)Install the fuel filter on the bracket. Tighten the filter 3/
4 to 1 circle by hand after the filter contacts the
bracket.
Fuel-Filter Changeover Cock Position
(g)Place the fuel filter handle to L-PURGE, R-OPEN
position. Left air vent plug, Right air vent plug,
(h)Loosen the air vent plug of the left fuel filter. sealing washer sealing washer
(i)When the fuel flowing from the vent hole no longer

Bracket Changeover
contains air bubbles, tighten the air vent plug. handle
(j)Place the fuel filter handle to L-OPEN, R-CLOSE posi- Apply clean fuel
to the packing
tion.
(k)Remove the right two fuel filters with a filter wrench.
(l)Repair new fuel filters and apply clean fuel to the pack- Right fuel
Left fuel
ing. filter filter
(m)Install the fuel filter on the bracket. Tighten the filter Fuel Filter (Cartridge Type) - Replace
3/4 to 1 circle by hand after the filter contacts the
bracket.
(n)Place the fuel filter handle to L-OPEN, R-PURGE
position. Loosen the air vent plug of the right fuel fil-
ter.
(o)When the fuel flowing from the vent hole no longer
contains air bubbles, tighten the air vent plug.
(p)Return the handle to the OPERATION position.
(q)Keep the no-load low-idling operation for several min-
utes.
(r)Check fuel leak from the fuel filter. If leakages are
found, loosen the fuel filter and check the packing for
seating or damage. Then retighten the fuel filter.
99089-40100
9-17
3.2.2 Fuel filter - Assemble

Changeover-type fuel filter (cartridge-type)
Changeover-Type Fuel Filter (Cartridge-Type) - Assemble
9-18 99089-40100
3.3 Injection Nozzle - Disassemble and Inspect

Fuel Injection Start Pressure - Inspect
Fuel Injection Nozzle Jet Plume - Check
3.3.1 Injection Nozzle - Disassemble
Looseness
2
Replace
3
1
Corrosion, wear, damage 8
5
fatigue
7 Carbon deposition
Clogging of orrifice
4
Wear, damage Crack
Injection Nozzle - Disassemble

1 Fuel inlet connector 6 Spacer
2 Cap nut, Nut, Gasket 7 Push rod, Nozzle spring, Spring seat
3 Adjusting screw 8 Nozzle holder body
4 Retaining nut
5 Nozzle tip
99089-40100
9-19
3.3.2 Fuel Injection Start Pressure - Inspect and

Adjust Nozzle tester
P/N: 05209-02100
Never touch the fuel injection nozzle orifice during

nozzle injection test.
(1) Install the fuel injection nozzle on the nozzle tester.

(2) Push down the handle at a speed of one stroke per sec-
ond and measure the pressure when the injection starts.
If the pressure is out of the standard, adjust.
Fuel Injection Start Pressure - Inspect
(3) To adjust the injection start pressure, remove the cap
nut on the nozzle holder body, loosen the lock nut and
turn the adjusting screw with a screwdriver. Tighten to Adjusting
screw
increase the injection start pressure or loosen to
decrease.
(4) After adjustment, tighten the lock nut and cap nut to the
specified torque. 39 to 49 N・m
{4 to 5 kgf・m} Lock nut
(5) Check the injection start pressure again after tightening [29 to 36 lbf・ft]
the cap nut to verify that the pressure is in the standard Cap nut 29 to 39 N・m
value. {3 to 4 kgf・m}
[22 to 29 lbf・ft]
Fuel Injection Start Pressure - Adjust
34.8 to 35.3 MPa
34 MPa
Fuel injection start- {354.9 to 360.0 kgf/cm2}
{347 kgf/cm2}
ing pressure [5047.3 to 5119.8 psi]
[4931 psi]
(the value when it is new)
3.3.3 Fuel Spray - Inspect

(1) When adjusting the nozzle opening pressure with the Faulty injection
nozzle tester, inspect the nozzle orifice clogging, fuel
spray pattern or check if fuel is dripping. If the spray
condition is faulty, clean or replace the nozzle tip.
(2) Strongly press down the nozzle tester handle to see the
spray condition. When the nozzle condition is good, the Good Large After Multi-stage Swirl
plume dribble injection injection
plumes starts simultaneously from the 10 orifices with a
angle
cone angle of 160°, the plume shows neat cone shape
made of fine mist without containing large droplets,
Nozzle Spray Condition - Check
and no fuel oil droplet remains on the orifice after the
injection.
Note: The orifice number and cone angle differ depending on
the application. Confirm the specification sheet. The
typical cone angles are as below:

Cone angle 160°
160°
Nozzle Cone Angle - Check
9-20 99089-40100
3.3.4 Nozzle Tip - Clean and Replace
(a) Be careful not to hit the nozzle tip point.

(b) The needle valve and body are precision parts. Adjusting
screw Lock nut
Handle them carefully, and do not change the
original valve and body combination.
(1) The spring pressure is applied to the nozzle needle
valve. Remove the cap nut and loosen the lock nut to
allow an easy turning of adjusting screw with a screw
driver. Adjusting Screw - Adjust
(2) Loosen the retaining nut and remove the nozzle tip.
Nozzle tip - Replace

(3) Wash the needle valve and body in clean kerosene or
diesel fuel oil, then assemble them in clean fuel oil.
(4) Apply Moly LG Grease No. 2 (SUMICO) to the nozzle
tip bearing face contacting to the retaining nut, install
the nozzle tip to the holder, apply Moly LG Grease No.
2 (SUMICO) to the thread of retaining nut, and tighten
the retaining nut to the specified torque. Needle valve
Body
Retaining nut tightening torque
98 to 127 N·m {10.0 to 13.0 kgf·m} [72.28 to 93.67 lbf·ft]
(5) If the spray pattern is still faulty after cleaning and Nozzle Tip - Clean
adjusting, change the nozzle tip with a new one.
Note: New nozzle tips are coated with anti-corrosive agent.
Wash the nozzle tips before use. First wash them in Moly LG grease
wash oil, and wash it again in clean diesel fuel before No.2 apply
installation.
Nozzle Tip - Install
99089-40100
9-21
3.3.5 Fuel Injection Nozzle - Assemble
29 to 39 N・m {3 to 4 kgf・m}
[22 to 29 lbf・ft]
39 to 49 N・m {4 to 5 kgf・m}
[29 to 36 lbf・ft]
88 to 98 N・m {9 to 10 kgf・m}
[65 to 72 lbf・ft]
ࠉApply Moly LG Grease No.2

Retaining nut threads
Nozzle tip shoulder
98 to 127 N・m {10 to 13 kgf・m}
[72 to 94 lbf・ft]
Fuel Injection Nozzle - Assemble
After completing assembly, start the engine and check for leak at the fuel inlet connector joint.
Be sure to tighten the retaining nut to the specified torque. The excessive tightening of retaining nut can harm
smooth movement of the needle valve and result in abnormal exhaust smoke or needle valve sticking.
9-22 99089-40100
3.4 Governor Drive - Disassemble, Inspect and Assemble

3.4.1 Governor Drive - Disassemble and Inspect
Woodward Governor, Ltd. make mechanical/hydraulic governor
Replace
Rotation
2
4
Abnormality and wear of 6
gear and spline section 4
3
8
Rotation
Abnormality and wear of gear
Abnormality and wear of Rotation

gear and spline section
Replace
8
7
5
Governor Drive - Disassemble and Inspect

1 Governor, Nut, Washer 5 Drive gear
2 Bearing, Packing, Snap ring 6 Bearing, snap ring, Washer
3 Driven gear 7 Bearing, Snap ring
4 Drive gear, Nut, Lock washer, Key 8 Case, Bolt, Washer, Stud, O-ring
Note: Consult Woodward Governor, Ltd. or its authorized agent for the inspection and repair of the governor body.
99089-40100
9-23
3.4.2 Governor Drive - Inspect, Replace

(1) Bearing Fitting Faces, Inside and Outside - Check
Rotate the bearing and if the rotation is not smooth, replace the bearing with a new one. Measure the bearing fitting faces of
drive and driven gears. Replace with a new one if the value exceeds the limit. Measure the fitting faces between the case and
bearing. Replace with a new one if the value exceeds the limit.
UG8 type, UG-ACTUATOR type, UG25+ type, EG10P type

Nominal value Standard value Limit value
governor
51.993 to 52.012 mm
Case-bearing housing inside diameter
[2.0470 to 2.0477 in.]
ø52 mm [2.05 in.] -
51.987 to 52.000 mm
Bearing outside diameter
[2.0467 to 2.0472 in.]
-0.025 to 0.007 mm -0.05 mm
[-0.0010 to 0.0003 in.] [-0.0020 in.]
61.993 to 62.012 mm
[2.4407 to 2.4414 in.]
ø62 mm [2.44 in.] -
61.987 to 62.000 mm
[2.4404 to 2.4409 in.]
-0.025 to 0.007 mm -0.05 mm
[-0.0010 to 0.0003 in.] [-0.0020 in.]
Drive gear side
24.990 to 25.000 mm
Bearing inside diameter
[0.9839 to 0.9843 in.]
ø25 mm [0.98 in.] -
Drive-gear-bearing fitting-position outside 25.002 to 25.015 mm
diameter [0.9843 to 0.9848 in.]
0.020 to 0.025 mm -0.05 mm
[0.0008 to 0.0010 in.] [-0.0020 in.]
29.990 to 30.000 mm
[1.1807 to 1.1811 in.]
ø30 mm [1.18 in.] -
Drive-gear-bearing fitting-position outside 30.002 to 30.015 mm
diameter [1.1812 to 1.1817 in.]
0.020 to 0.025 mm -0.05 mm
[0.0008 to 0.0010 in.] [-0.0020 in.]
61.993 to 62.012 mm
[2.4407 to 2.4414 in.]
ø62 mm [2.44 in.] -
61.987 to 62.000 mm
[2.4404 to 2.4409 in.]
-0.025 to 0.007 mm -0.05 mm
[-0.0010 to 0.0003 in.] [-0.0020 in.]
Driven gear side
29.990 to 30.000 mm
[1.1807 to 1.1811 in.]
ø30 mm [1.18 in.] -
Driven-gear-bearing fitting-position outside 30.002 to 30.015 mm
diameter [1.1812 to 1.1817 in.]
0.020 to 0.025 mm -0.05 mm
[0.0008 to 0.0010 in.] [-0.0020 in.]
9-24 99089-40100
3.4.3 Governor Link - Check

(1) Ball Joints Relating to the Fuel Control Link - Check
0.1 mm Ball joint
Check looseness of ball joints used in the fuel control link [0.004 in.]
and others.
If the amount of looseness is 0.1 mm [0.004 in.] or more, 0.1 mm
[0.004 in.]
replace the ball joint with a new one.
Note:(a) Record the ball joint length before disassembling
the ball joint and rod. Make marks to show the ball Rod
joint assembled direction to ensure the correct reas-
Lever
sembling.
Ball Joint - Check for Looseness
(b) Be sure to tighten the nut when installing the ball
joint. Nut
Ball joint
Control link
Lever
Washer
Nut
Ball Joint - Replace
99089-40100
9-25
3.4.4 Governor Drive - Assemble

Woodward Governor, Ltd. make mechanical/hydraulic governor
Backlash: 0.04-01
[0.0016 - 0.0043]
Governor Drive - Assemble

Note: Backlash 0.04-01
9-26 99089-40100
3.5 Fuel Filter - Disassemble, Inspect and Assemble

3.5.1 Fuel Pump (Trochoid Type) - Disassemble and Inspect
5
4
6
2 Replace
Lip face wear, damage,

5 deterioration
2
Fuel Pump (Trochoid Type) - Disassemble and Inspect

1 Fuel pump, Bolt, Washer 4 Bushing
2 Shaft, Set screw, Nut 5 O-ring
3 Bushing 6 Adapter
99089-40100
9-27
Shaft - Install
When removing the shaft with a sliding hammer, be careful not to get caught your fingers between the sliding ham-
mer weight and bar or plate.
(1) The shaft is tapped in the fuel pump shaft. Install the
Sliding hammer
adaptor to the sliding hammer to pull out. P/N: 41091-01300
(2) Use a hexagonal wrench of 2.5 mm [0.098 in.] width Plate
2 Weight
across flats to remove the set screw.
Screw-in until
Screw-in to the tip contacts Bar
the incomplete Adapter the bottom
thread P/N: 41091-07500
Shaft - Remove
3.5.2 Fuel Pump (Trochoid Type) - Inspect and
Oil seal case
Replace Bearing
O-ring
Oil seal
(1) Oil Seal - Replace Oil seal
Pump body
(a)Remove the woodruff key and snap ring on the shaft,
then remove the oil seal. Snap ring
(b)Apply grease to the new oil seal inside and outside Shaft
lips. Fill grease in the oil seal, then install the oil seal.
(c)Install the snap ring, and fill grease in the snap-ring
groove.
Note:(a) Use a flat tip driver or the like to remove the oil seal
Oil Seal - Replace
paying attention not to damage the shaft and oil seal
case.
(b) Pay attention not to damage the O-ring at the snap-
ring groove when installing the O-ring to the pump
body after the oil seal case installation.
(2) Fuel Pump (Trochoid Type) - Replace
Replace the fuel pump (trochoid type) as an assembly when
the replacement is required.
Note: The consisting parts other than the oil seal, oil seal case
and O-ring are not supplied as service parts.
9-28 99089-40100
3.5.3 Fuel Pump (Trochoid Type) - Assemble
Apply engine oil to oil seal lip

Shaft
Fuel Pump (Trochoid Type) - Assemble
99089-40100
9-29
Shaft - Install
When installing the shaft with a sliding hammer, be careful not to get caught your fingers between the sliding ham-
mer weight and bar or plate.
(1) Use the sliding hammer, not a hammer, to install the

Sliding hammer
shaft to fuel pump. PN: 41091-01300
Note: Tapping the shaft with a hammer results in spline dis- Plate
Set screw Weight
torsion. And the insertion to the governor gear spline
becomes difficult.
(2) Use a hexagonal wrench of 2.5 mm [0.098 in.] width
across flats to install the set screw. Screw-in until
(3) Apply an even coat of clean engine oil to each part to Screw-in to the tip contacts Bar
assemble. the incomplete Adapter the bottom
hread P/N: 41091-07500
Shaft - Install
3.6 Fuel oil return relief valve (1CV-type injection pump only.)
3.6.1 Fuel Oil Return Relief Valve - Inspect
In the case of new-type relief valve (41061-06900) Cap
(1) Measure the valve opening pressure.
(2) Remove the cap and loosen the lock nut, then the
adjusting bolt can be turned. Tighten the adjusting bolt
to raise the valve opening pressure, or lossen to
decrease.
Fix the adjusting bolt with the lock nut after adjusting Lock nut
the valve opening pressure. Adjusting bolt

If the pressure does not change even after the adjusting,
Fuel Oil Return Relief Valve (New Type) - Inspect
replace the valve spring.

0.25 ± 0.02 MPa
Valve opening pressure {2.55±0.20 kgf/cm2}
[36.26 ± 2.90 psi]
(3) Reface the valve seat face, if the seat face is worn.
Replace if the wear is excessive.
9-30 99089-40100
4. Fuel System - Install

To install, follow the removal sequence in reverse. (See the illustration for disassembly.)
Thoroughly clean fuel passages and dry them well.
4.1 Fuel Injection Pump and Fuel Pipe - Install
5 Injection pump setting bolt

3 Oil pipe union bolt
1 Fuel injection pipe cap nut
Cylinder
head
2 Fuel injection pipe cap nut
Crankcase
4 Oil pipe union bolt
Bolts Around Fuel Injection Pump - Tighten
4.1.1 Bolts Around Fuel Injection Pump - Tighten
No. Item Tightening torque Special Tools

59±1 N·m Spanner head 41091-08200
1 Fuel-injection pipe cap nut {6.0±0.10 kgf·m}
[43.52 ± 0.73 lbf·ft] Torque wrench 41091-08100
Spanner head (continuous-use spec.)

41091-08400
1CV type 88±1.0 N·m
2 Fuel-injection pipe cap nut {9.0±0.10 kgf·m} Spanner head (emergency-use spec.)
[64.91 ± 0.73 lbf·ft] 41091-08500
Torque wrench 41091-08100
15 ± 2 N·m
3 Oil pipe union bolt {1.5 ± 0.20 kgf·m} -
[11.06 ± 1.47 lbf·ft]
34 ± 4 N·m
4 Oil pipe union bolt {3.5 ± 0.40 kgf·m} -
[25.08 ± 2.95 lbf·ft]
167±17 N·m
5 Injection pump setting bolt {17.0±1.73 kgf·m} In the case of 1CV-type injection pump
[123.17 ± 12.53 lbf·ft]
99089-40100
9-31
4.2 Fuel Filter, Fuel Pump and Fuel Pipe - Install

Changeover-type (Cartridge-type) Oil Filter Spec.
Right injection pump

147±15 N･m
{15.0±1.5 kgf･m}
[108±11 lbf・ft]
147±15 N･m Timing gear case

{15.0±1.5 kgf･m}
[108±11 lbf・ft]
Air duct
Left injection
pump
Control link A
Bearing
147±15 N･m
{15.0±1.5 kgf･m}
Fuel pump [108±11 lbf・ft]
Fuel Filter, Fuel Pump and Fuel Pipe - Install

(Changeover type - cartridge type - oil filter spec.)
9-32 99089-40100
4.3 Governor Control Link - Install
Fatigue, wear
Align the matching marks to
ensure the assembling condition
Adjust the distance between

ball joints to the value recorded at
disassembly an install the ball joints in
the same direction as that before
disassembly by aligning matchmarks.
Crankcase
Timing
gear case
Governor Control Link - Install

Note:(a) Check the ball joint length to be the same as that measured before disassembling. Then assemble the ball joint and rods.
Assemble the ball joint aligning the markings made before disassembling.
(b) Assemble the lever and shaft connected at the serration aligning the markings made before disassembling.
(c) Refer to "LUBRICATION SYSTEM" for the parts in ---.
99089-40100
9-33
4.4 Fuel Control Link - Install

Note:(a) Check the ball joint length to be the same as that measured before disassembling. Then assemble the ball joint and rods.
Assemble the ball joint aligning the markings made before disassembling.
(b) Assemble the lever and shaft connected at the serration aligning the markings made before disassembling.
Align to the serrartion

matching marks
Adjust the distance between ball

joints to the value recorded at
disassembly an install the ball
joints in the same direction as that
before disassembly by aligning
matchmarks.
Fuel Control Link - Install
9-34 99089-40100
4.5 Control shaft assembling procedure
An assembling error of cam-chamber control link results in the overrun. Be sure to install in the proper way.
4.5.1 Control Shaft - Install

Adjusting screw Snap ring
(1) Insert the control shafts 6 and 7, two levers 1 and 2, Lever B
bearings 3 and 4 and connecting collar 5 for shaft Lever A Controll
Nut Shaft
installation into the cam chamber inspection window,
and assemble them in the crankcase.
Apply an even coat of clean engine oil to bearings.
Finger tighten the bolts and nuts.
(2) Rotate the control shaft 6 lightly by hand. Check the ø5mm round bar
[0.19685in.]
rotation and then tighten the bearing setting bolts to the
Rearmost bearing
specification. Install the snap ring 4 at the rearmost
Control Shaft - Install
bearing both sides.
4.5.2 Control Lever and Injection Pump Rack - Con-

rack stop Fuel lever
nect Lever B
(1) Align the rear most bearing hole and control shaft hole. Lever A
Control rack
Insert the ø5 mm round bar to fix the rotation of control Pin Nut
Standard
shaft. injection
(2) Place the lever-A adjusting screw at the middle position amount
Lever B Position line
to allow tightening and loosening. Fix it with a nut. (Rack position18)
(3) Pull the injection-pump control rack fully near side No-injection assured
Controll position
(rack stop position). And connect the lever B and fuel Shaft Rack stop position line
lever with a pin, and fix with a nut. Lver A Bolt ( Rack position 0)
Control Lever and Injection Pump Rack - Connect
(4) Tighten the fixing bolt of lever A, and fix it to the con-
trol shaft.
99089-40100
9-35
4.5.3 Right and Left Control Links - Connect

Shaft D Connect by aligning to
(1) Attach the lever C 8 at the rear end of control shaft. Lever E the maching mark.
Note:(a) Connect the serration aligning the markings made
before disassembling. Align the Align the
Rod F distance
(b) Make sure that the lever C is install in a almost hor- distance
and Lever C and
izontal position. direction. direction.
(2) Install the shaft D and lever E at the front end of gover-
nor-side control shaft.
Connect by aligning to the maching mark.
Note: Connect the serration aligning the markings made be-
fore disassembling. Engine left side Engine right side
Right and Left Control Links - Connect
(3) Fix the ball joint to the rod F. Adjust the length of ball
joint to the length recorded before the disassembling,
and connect the lever C and lever E.
4.5.4 Control Shaft and Governor Terminal Shaft -

Lever I
Connect Align he distance
and direction
Lver G
Check the tightness of connecting bolts and nuts in a
Governor
sequence, and make sure that the links are properly
Rod H
connected after assembling the fuel control link.
(1) Install the lever G to the governor terminal shaft by Connect by aligning
to the maching mark. Governor
connecting the serration aligning the markings made terminal shaft
Lever G and Lever I - Connect
(2) Adjust the ball joint to the length and direction before
disassembling, and fix it to the rod H with nut. Connect
the lever G and lever I.
(3) Remove the ø5 mm round bar inserted in the rearmost
bearing.
9-36 99089-40100
4.6 Stop System - Install
1
7
7
1
6
3
6
5
5
5
2
Stop System - Install

Note: Install while aligning the bolt 7 fixing position marked before disassembling.
99089-40100
9-37
1. Lubrication System - Remove and Inspect ......................................................... 10-3
1.1 Fuel Feed Pipe to Injection Pump and Governor Lubricating Oil Pipe - Remove and Inspect10-3
1.2 Turbocharger Lubrication Oil Pipe - Remove and Inspect...................................................... 10-4
1.3 Turbocharger Drain Pipe - Remove and Inspect .................................................................... 10-5
1.4 Oil Pump and Oil Pipe - Remove and Inspect ........................................................................ 10-6
1.5 Oil Filter, Oil Cooler, Oil Thermostat Case and Oil Pipe - Remove and Inspect..................... 10-7
1.6 Bypass oil Filter and Oil Pipe - Remove and Inspect.............................................................. 10-9
1.7 Oil Level Gauge, Oil Filler and Breather - Remove and Inspect........................................... 10-10
2. Lubrication System - Disassemble, Inspect, and Assemble ........................... 10-11
2.1 Oil Pump and Safety Valve - Disassemble and Inspect ....................................................... 10-11
2.2 Oil Pump and Safety Valve - Inspect .................................................................................... 10-12
2.3 Oil Pump and Safety Valve - Assemble................................................................................ 10-14
2.4 Oil Filter, Relief Valve and Left Oil Cooler - Disassemble and Inspect................................. 10-15
2.5 Oil Filter and Relief Valve - Inspect ...................................................................................... 10-17
2.6 Oil Filter and Relief Valve - Assemble .................................................................................. 10-18
2.7 Oil Cooler and Oil Thermostat - Disassemble, Inspect and Assemble ................................. 10-21
3. Lubrication System - Install................................................................................ 10-25
3.1 Fuel Feed Pipe to Injection Pump and Governor Lubricating Oil Pipe - Install..................... 10-25
3.2 Turbocharger Lubrication Pipe - Install................................................................................. 10-26
99089-40100
10-1
1. Lubrication System - Remove and Inspect

1.1 Fuel Feed Pipe to Injection Pump and Governor Lubricating Oil Pipe - Remove and Inspect
Replace
Replace Replace 9
Replace
9
8
9 9
5
9 6 4 Replace
2
1
2
1 1
2 1 2
1 2
2 1
1 2 Governor
2 1
1 2
1
2 5
1
3 1 2 Replace
8 7 2
Replace
4
Replace Replace
5
6
3 1 Injection
pump Replace
1
1 Replace
3 Injection
3 2
pump
Replace
Replace
Fuel Feed Pipe to Injection Pump and Governor Lubricating Oil Pipe - Remove and Inspect
Removal sequence
1 Oil pipe, Union bolt, Sealing washer, Connector 6 Oil pipe, Union bolt, Sealing washer
2 Oil pipe, Union bolt, Sealing washer 7 Oil pipe, Union bolt, Sealing washer
3 Oil pipe, Union bolt, Sealing washer 8 Oil pipe, Union bolt, Sealing washer
4 Oil pipe, Union bolt, Sealing washer 9 Oil pipe, Union bolt, Sealing washer, Connector, plug
5 Oil pipe, Union bolt, Sealing washer
99089-40100
10-3
1.2 Turbocharger Lubrication Oil Pipe - Remove and Inspect
2 2
Replace 1
Replace
Replace
Replace 3
3
Replace Replace 4
4
Replace
Replace
8
7 Replace
6
Replace
5
Crankcase
7 Replace FORWARD
Turbocharger Lubrication Oil Pipe - Remove and Inspect

Removal sequence
1 Bracket, Pipe support, Bolt, Washer 4 Joint
2 Oil pipe, Gasket, Bolt, Washer, Packing 5 Bracket, Pipe support, Bolt, Washer
3 Oil pipe, Gasket, Bolt, Washer, Packing 6 Bracket, Pipe support, Bolt, Washer
7 Oil pipe
8 Bolt, Washer, Oil pipe
10-4 99089-40100
1.3 Turbocharger Drain Pipe - Remove and Inspect
7
Replace
Replace 2
5 Replace
Replace
3
A
6
Replace
1
1
2 A
6 4
4 5
Replace 1
3
1
4
Replace
Replace
1 Replace FORWARD
Turbocharger Drain Pipe - Remove and Inspect

Removal sequence
1 Drain pipe, Bolt, Washer, Packing 5 Coupling
2 Packing 6 Drain pipe, Packing, Bolt, Washer
3 Bracket, Pipe support, Bolt, Washer 7 Packing
4 Drain pipe, Packing
99089-40100
10-5
1.4 Oil Pump and Oil Pipe - Remove and Inspect
8
Replace
Replace
Crankcase
8
7 8
5
Replace
Cam chamber (right side)
9
5 Distributor
Replace
10
5
Replace
Replace
11
6
Water pump
4
Water pump
1 Replace
Front gear
case Replace
Front
Replace
1
2
1 1
3
Oil Pump and Oil Pipe - Remove and Inspect
Removal sequence
1 Oil pipe, Bolt, Washer, O-ring 7 Oil pipe, Connector
2 Oil pipe, Bolt, Washer, O-ring 8 Oil pipe, Connector, T-joint, Clamp, Protect rubber
3 Oil pump, Nut, Washer 9 Oil pipe, Clamp, Protect rubber
4 Oil pipe, Bolt, Washer, O-ring 10 Oil pipe, T-joint
5 Oil pipe, Bolt, Washer, O-ring 11 Oil pipe, Clamp, Protect rubber
6 Valve case, Bolt, Washer, Gasket
10-6 99089-40100
1.5 Oil Filter, Oil Cooler, Oil Thermostat Case and Oil Pipe - Remove and Inspect
4
9 Replace
4 B
9 4
Replace 9
5 4
4
9 RELIEF 5
VALVE Replace 5
10 5 Replace
10 Replace 1
14 4
14 5 B OIL PUMP 1 1
10
10 A
3 2 2
10 10 1
10 A 1
10 3 1
10 2
11 1
14 1
Replace Replace
14 8 Replace
14 13 2
11 12
11 8 2
7
Replace
8 7
11 11 8
11
12
13 7 6
13 7 6
12 13 13
13 7 6
13
13 13
11 6 Replace
13
11
11
12 14 12
11
Replace
14 11
11
11
14 14 11
14
Replace
Oil Filter, Oil Cooler, Oil Thermostat Case and Oil Pipe - Remove (1)
Removal sequence
1 Oil pipe, Bolt, Nut, Washer, O-ring 9 Oil pipe, Bolt, Washer, O-ring
2 Oil pipe, Bolt, Washer, O-ring 10 Oil pipe, Bolt, Washer, O-ring, Taper plug
3 Oil pipe, Bolt 11 Oil pipe, Bolt, Washer, O-ring
4 Oil pipe, Bolt, Washer, O-ring 12 Oil filter, Bushing, Valve, Oil pipe, Bolt, Washer
5 Oil pipe, Bolt, Washer, O-ring 13 Connector, Oil pipe, Bolt, Washer, O-ring
6 Oil pipe, Bolt, Washer, O-ring 14 Gasket, Oil pan, Taper plug
7 Thermostat housing, Thermostat, Bolt, O-ring
8 Oil pipe, Taper plug, Bolt, Washer, O-ring
99089-40100
10-7
Replace
17
17
17
17
18
9 Replace
19 19
A
19 B
21
Replace
9 10
9
21 20 4 4 A
8
Replace
8
8 7 11 B
4
8
8 5
9
Replace
6 1
6
2
13 6
13 3
22 3
13
Replace 16 Replace
13 11 16
3
16
12
11
22
11
14
16
22
15
14
14
Replace 14
14
Oil Filter, Oil Cooler, Oil Thermostat Case and Oil Pipe - Remove (2)
Removal sequence
1 Water pipe, Bolt, Washer, O-ring 13 Water pipe, Bolt, Washer, O-ring, gasket
2 Coupling 14 Packing, Water pipe, Bolt, Washer
3 Water pipe, Bolt, Washer 15 Coupling
4 Water pipe, Bolt, Washer, O-ring 16 Water pipe, Bolt, Washer, O-ring, Gasket
5 Coupling 17 Water pipe, Bolt, Washer, O-ring, Gasket
6 Water pipe, Bolt, Washer 18 Gasket
7 Coupling 19 Water pipe, Bolt, Washer, Taper plug
8 Bypass pipe, Bolt, Washer, Gasket, Cover, O-ring 20 Coupling
9 Water pipe, Bolt, Washer, O-ring 21 Water pipe, Bolt
10 Thermostat 22 Oil cooler, Connector, Valve, Pipe
11 Packing, Water pipe, Bolt, Washer
12 Coupling
10-8 99089-40100
1.6 Bypass oil Filter and Oil Pipe - Remove and Inspect
B 4
2
2
4
1
B 4
㸿 4
4
2
1 1
1
56
3
8 6
9 Replace 1
2 1
10 1
11 㸿 4
5 Replace
2
11 2
4
Replace 8 9
7
OIL PUMP
7 1
4
7 4
7 4
2
7
7
7 1 1
1
Replace
7 3
7
Replace 1
1
1
Bypass oil Filter and Oil Pipe - Remove and Inspect

Removal sequence
1 Oil drain pipe, Clamp, Connector, Bolt, Washer 7 Bolt, Washer, Nut, Clamp, Oil pipe, Connector
2 Bolt, Washer 8 U-bolt, Washer, Nut
3 Bypass filter 9 Connector
4 Stay, Side cover 10 Valve
5 Bolt, Washer 11 Valve stay, Bolt, Washer
6 Joint, Oil pipe
99089-40100
10-9
1.7 Oil Level Gauge, Oil Filler and Breather - Remove and Inspect
1
Replace
Replace
Replace
2
5
2
2 5
Oil Level Gauge, Oil Filler and Breather - Remove and Inspect
Removal sequence
1 Breather element, Bolt, Washer 4 Oil level gauge, Oil level gauge pipe, Elbow
O-ring, Flange 5 Oil filler, Oil filler cap, Screen, bolt, Washer, Packing
2 Breather body, Connector, Bolt, Washer, O-ring
3 Oil drain pipe, Elbow
10-10 99089-40100
2. Lubrication System - Disassemble, Inspect, and Assemble

2.1 Oil Pump and Safety Valve - Disassemble and Inspect
Gear defect, wear
Replace
Spring fatigue,
break, wear Wear 6
Wear 3
Replace: Gasket
1
Wear
Wear, damage 5
2
6
7
4
5 Gear defect, wear
8
Replace
2
Replace
8
8
Oil Pump and Safety Valve - Disassemble and Inspect

1 Oil pump gear, Nut, Lock washer 5 Bushing
2 Pump cover, Bolt, Washer, O-ring, Packing 6 Bushing
3 Drive gear, Key 7 Pump case, Pin, O-ring
4 Driven gear 8 Safety valve, Valve case, Bolt, Washer
99089-40100
10-11
2.2 Oil Pump and Safety Valve - Inspect

2.2.1 Drive gear and driven gear
backlash measurement
Measure the backlash between drive gear and driven gear. If
the value exceeds the limit, replace the gears with new ones.

Drive gear and driven 0.2 to 0.4 mm 0.5 mm
gear backlash [0.008 to 0.016 in.] [0.020 in.]
2.2.2 Top Clearance Between Gear Teeth and Case -

Measure Feeler gauge
Measure the top clearance between the drive and driven
gear teeth and case housing. If the value exceeds the limit,
replace the gear or the case with a new one.

Top clearance between 0.25 to 0.37 mm 0.38 mm
gear teeth and case [0.0098 to 0.0146 in.] [0.0150 in.]
Top Clearance Between Gear Teeth and Case -

Measure
2.2.3 Drive Gear and Driven Gear Tooth Flank -
Inspect
Check the tooth flank and replace the gear if it is defective.
2.2.4 Side Clearance Between Gear Width and Case
- Measure
Measure the side clearance between the drive/driven gear
width and case without packing. If the value exceeds the
limit, replace the gear or the case with a new one.

Side clearance between gear 0.15 to 0.21 mm 0.24 mm
width and case depth [0.0059 to 0.0083 in.] [0.0094 in.]
Side Clearance Between Gear Width and Case -

Measure
10-12 99089-40100
2.2.5 Drive/Driven Gear Shaft and Bushing Outside

Diameters and Bushing Inside Diameters -
Measure
Measure the drive/driven gear shaft outside diameters and
bushing inside diameters. Replace the bushing or shaft with
a new one if it is excessively worn or the measured value
exceeds the limit.
Measurement item Nominal value Standard value Limit value

ø44 mm 43.984 to 44.000 mm
Shaft diameter -
[1.73 in.] [1.7317 to 1.7323 in.]
ø44 mm 44.200 to 44.230 mm
[1.73 in.] [1.7402 to 1.7413 in.]
0.200 to 0.246 mm 0.3 mm
Clearance between shaft and bushing -
[0.0079 to 0.0097 in.] [0.012 in.]
2.2.6 Oil Pump Bushing - Replace

To replace the bushing: Press in the new bushings to the oil
pump case side and cover side. Use the bushing as it is with-
out processing the bushing inside diameter.
2.2.7 Safety Valve - Inspect
Measure the safety-valve opening pressure. Adjust the shim Shim
thickness between the spring and cap nut if the pressure is
not within the standard value.
When the valve is disassembled, check the valve seat faces
and replace with a new one if excessively worn.

1.18 MPa 1.08 to 1.27 MPa
Safety valve opening
{12 kgf/cm2} {11 to 13 kgf/cm2}
pressure
[171 psi] [156 to 185 psi] Safety Valve - Inspect
92 mm [3.62 in.]/
Safety valve spring set 660 to 728 N
-
length/load {67.2 to 74.2 kgf}
[148.37 to 163.66 lbf]
99089-40100
10-13
2.3 Oil Pump and Safety Valve - Assemble
245 N･m {25 kgf･m}

[181 lbf・ft]
Apply Moly LG grease No.2
to the seat face.
Apply ThreeBond 1215 or equivalent

to the packing both faces.
Oil Pump and Safety Valve - Assemble

Note:(a) Apply an even coat of clean engine oil to each part to assemble.
(b) Apply a hydraulic pressure of 0.98 MPa {10 kgf/cm2} [142 psi] to the seat to check the leak after the safety valve as-
sembling.
10-14 99089-40100
2.4 Oil Filter, Relief Valve and Left Oil Cooler - Disassemble and Inspect
Oil filter (changeover type)
1
1
Replace
2
Replace
8
6
Replace Replace
4
6
Replace
6
Replace 7
Oil Filter (Changeover Type) - Disassemble and inspect

1 Cover, Bolt, Nut 6 Changeover cock, Bolt, O-ring
2 Wing nut, Packing 7 Flange, Lower case, Packing
3 Element 8 Cover, Bolt, Washer, O-ring
4 Body, Bolt, Packing 9 Body
5 Packing, O-ring
Note: Refer to the oil filter manufacturer service manual for the disassembling, inspection, and replacement.
99089-40100
10-15
Bypass Oil Filter (Cartridge Type)
5
4
4
3
Replace
Replace
Replace
1
2
2
1
Replace
Bypass Oil Filter (Cartridge Type) - Disassemble and Inspect

1 Cover, Bolt, Nut, Washer, O-ring 4 Bracket, Bolt, Nut, Washer, O-ring
2 Bypass oil filter 5 Cover
3 Bracket, Bolt, Nut, Washer, O-ring
10-16 99089-40100
2.5 Oil Filter and Relief Valve - Inspect

2.5.1 Oil Filter Element Cartridge - Inspect
On the occasion of oil filter replacement, disassemble the
oil filter and bypass oil filter to check metal particles and
others on the element. If a defect is shown, cut the element
or cartridge and pull out the filtering paper. Check the color
and shape of metal particles to know the cause.
Cartridge - Check
2.5.2 Relief Valve Opening Pressure - Measure and
Adjust
Warm up the engine until the oil temperature is stabilized.
Measure the oil pressure at the low-idling and high-idling
speeds.
Reface the seat face to correct if the valve or bracket seat
face is worn. Replace with a new one if excessively worn.
Check the valve opening pressure to be in the standard.
Replace the valve spring and other inner parts with a new
one if the valve opening pressure is not in the standard.
Relief Valve Opening Pressure Adjustment
0.59 ± 0.05 MPa
Valve opening pressure {6.02±0.50 kgf/cm2}
[85.57 ± 7.25 psi]
99089-40100
10-17
2.6 Oil Filter and Relief Valve - Assemble

Oil Filter (Changeover Type)

Oil Filter (Changeover Type) - Assemble
10-18 99089-40100
Bypass Oil Filter (Cartridge Type)
Bypass Oil Filter (Cartridge Type) - Assemble
99089-40100
10-19
2.6.1 Governor Oil Filter (EG10P Type) - Replace

Eye bolt
Governor Air vent pipe
Filter bracket
Check the removed governor oil filter. If metal particles
or others are sticking on the element, ascertain the
origine and take a proper measure.
Tighten the cartridge oil filter by hand. Be careful not
to dent or scratch the surface of the governor oil filter.
Filter wrench
(1) Prepare a drip pan and place it below the governor oil
filter. Governor oil filter
(2) Remove the governor oil filter with a filter wrench. Governor Oil Filter - Replace
(3) Remove the oil that is stained on the filter mounting
surface of bracket with waste cloth. Apply engine oil.
(4) Prepare a new governor oil filter. Check the packing to
be snugly installed in the groove, and apply clean
engine oil to the packing.
(5) Install the new governor oil filter to the bracket fitting
face and fully tighten the filter by hand.
(6) Remove the union bolt on the air bleed pipe and fill up
engine oil in the governor oil filter.
(7) Tighten the union bolt to the specified torque.
Governor Oil Filter
8 ± 1 N·m
Union bolt tightening torque {0.8 ± 0.10 kgf·m}
[5.90 ± 0.73 lbf·ft]
(8) Start the engine and check oil leak.
10-20 99089-40100
2.7 Oil Cooler and Oil Thermostat - Disassemble, Inspect and Assemble
(41639-05000)
Replace
3 Clogging, break, crack
2
Replace
Oil Cooler (41639-05000) - Disassemble

1 Housing, Bolt, Washer, Gasket 3 Body
2 Housing, Bolt, Washer, Gasket
Note: To assemble, follow the disassembling sequence in reverse.

(Oil cooler weight: approx. 250 kg [551 lb.])
99089-40100
10-21
2 1
Replace
Replace
Oil Thermostat Disassembly

1 Thermostat case, Bolt, Washer, O-ring 2 Thermostat, O-ring
10-22 99089-40100
2.7.1 Oil Cooler and Oil Thermostat - Clean and

Inspect
Outlet
(1) Oil Cooler - Clean
(a)Inspect the fresh or sea water pipes visually to check
deposit of scale and others. If scale is observed, scrape
off the scale with a stick or the like paying attention
not to damage pipes, then rinse the scale by flowing
water.
Inlet
(b)Blow steam (mixture of hot water and compressed air:
0.29 to 0.69 MPa {3 to 7 kgf/cm2} [43 to 100 psi],
Oil Cooler - Clean
150°C [302°F] or below ) to the inlet and outlet of oil
system pipe to clean, then remove deposits and check
corrosion and crack.
(c)If the scale or deposit can not be removed in the pro-
cesses above, apply a chemical cleaning.
Note: Ask a cleaning specialist with much experience for the
chemical cleaning as it may cause a serious damage to
the device without proper treatment.
(d)Replace with a new one if excessively corroded or
cracked.
Oil Cooler Element - Clean

(2) Oil Cooler - Check Leak
(a)Immerse the oil cooler in water. In this condition, blow
compressed air (at a pressure of 0.4 MPa {4 kgf/cm2}
[57 psi]) to the oil passage to check air leak. Air leak
(b)Replace the part if it shows leak.
Oil Cooler - Check Leak
99089-40100
10-23
(3) Oil Thermostat - Inspect
Be careful of hot water and flames.

You may get burned or cause a fire.
(a)Put the oil thermostat fully into water in a container.
Heat the water while measuring water temperature.
Record the temperature at which the valve start to
open, and at which the valve lift becomes to the stan-
dard value.
(b)Replace the thermostat if a deviation from the standard Thermostat - Inspect
temperature is significant.
Note: Stir inside of the container with a stick to equalize the
temperature.
The set temperature of thermostat may differ accord-
ing to the customer's request. Verify the valve opening
temperature with stamped marks on the thermostat.
Opening temperature
stamp position
Valve Opening Temperature Stamp Position
Thermostat part number Measurement item Standard value

41039-00701
Temperature at which valve lift becoming 11 mm [0.43 in.] or more 70 to 75°C [158 to 167°F]
10-24 99089-40100
3. Lubrication System - Install

Install the parts in the reverse order of the disassemble sequence.
(1) Replace packings and O-rings with new ones when assembling.
(2) Thoroughly clean oil passages of each part with washing oil, and dry the cleaned parts with compressed air before assem-
bling.
3.1 Fuel Feed Pipe to Injection Pump and Governor Lubricating Oil Pipe - Install
15±2 N・m
34±4 N・m Injection pump {1.5±0.2 kgf・m}
{3.5±0.4 kgf・m} 98±10 N・m [11±1 lbf・ft]
[25±3 lbf・ft] {10.0±1.0 kgf・m}
[72±7 lbf・ft]
15±2 N・m
{1.5±0.2 kgf・m}
[11±1 lbf・ft]
Governor
98±10 N・m
{10.0±1.0 kgf・m}
[72±7 lbf・ft]
34±4 N・m
{3.5±0.4 kgf・m}
[25±3 lbf・ft]
34±4 N・m 98±10 N・m
{3.5±0.4 kgf・m} {10.0±1.0 kgf・m}
[25±3 lbf・ft] [72±7 lbf・ft]
15±2 N・m
{1.5±0.2 kgf・m}
[11±1 lbf・ft]
15±2 N・m
{1.5±0.2 kgf・m}
[11±1 lbf・ft] Injection pump
34±4 N・m
{3.5±0.4 kgf・m}
Injection pump
[25±3 lbf・ft]
Fuel Feed Pipe to Injection Pump and Governor Lubricating Oil Pipe - Install
99089-40100
10-25
3.2 Turbocharger Lubrication Pipe - Install
98 ± 10 N·m 98 ± 10 N·m
{10.0 ± 1.0 kgf·m} {10.0 ± 1.0 kgf·m}
[72 ± 7 lbf·] [72 ± 7 lbf·]
98 ± 10 N·m
{10.0 ± 1.0 kgf·m}
98 ± 10 N·m
[72 ± 7 lbf·]
{10.0 ± 1.0 kgf·m}
[72 ± 7 lbf·]
98 ± 10 N·m
{10.0 ± 1.0 kgf·m}
[72 ± 7 lbf·]
Crankcase
FORWARD
Turbocharger Lubrication Pipe - Install
10-26 99089-40100
3.2.1 Protect tape - Wind

Wind the oil splash protect tape when installing the turbo- Protect tape
PN: 83161-01600
charger lubrication pipe (4, 5, 6, 7, 8)
(1) Pull out the protect tape a little longer than the required
length. Cut the tape with scissors remaining the peeling
tape stuck.
(2) While removing the peeling tape, wind the protect tape
placing its printed face outside.
Note:(a) If the protect tape is winded after removing the all
peeling tape, dust and oil may stick to the adhesive
Protect Tape - Wind (1)
face, and functional degradation may result by the
adhesion defect. Wind the protect tape while re-
Oil pipe
moving the peeling tape.
(b) Wind the protect tape to overlap 1/3 of the width of Adhesive face
tape.
(c) To store the protect tape, be sure to stick the peeling
tape and store in a box avoiding a place uncovered Protect tape
from the direct sun light and ultraviolet rays.
Release film
Protect Tape - Wind (2)
99089-40100
10-27
1. Cooling System - Remove and Inspect ............................................................... 11-3
1.1 Thermostat and Water Pipe - Remove and Inspect................................................................ 11-3
1.2 Water Pipe - Remove and Inspect.......................................................................................... 11-4
2. Cooling System - Disassemble, Inspect, and Assemble ................................... 11-5
2.1 Water Pump - Disassemble and Inspect ................................................................................ 11-5
2.2 Thermostat - Disassemble and Inspect .................................................................................. 11-9
99089-40100
11-1
1. Cooling System - Remove and Inspect

1.1 Thermostat and Water Pipe - Remove and Inspect
8
Replace
6
Replace
7
5 6 Replace
5
3 Replace
Replace
3 5
3 Turbocharger
Bracket
3
4
Replace 1
4 1
Replace
1
2
Replace
2
Water pump
Thermostat and Water Pipe - Remove and Inspect

Removal sequence
1 Water pipe, Coupling, Bolt, Washer, O-ring 5 Water pipe, Bolt, Washer, O-ring
2 Water pipe, Bolt, Washer, O-ring 6 Water pipe, Flange, Bolt, Washer, O-ring
3 Water pipe, Coupling, U-bolt, Bolt, Nut, Washer, O-ring 7 Water pipe, Bolt, Washer, O-ring
4 Thermostatcase,Waterpipe,Coupling,Bolt,Washer,O-ring 8 Water pipe, Flange, Bolt, Washer, O-ring
99089-40100
11-3
1.2 Water Pipe - Remove and Inspect
Replace
7 9
Air cooler
Replace
Replace
Replace
8
Air cooler 6
5
Replace
Replace
6
4
Replace
Exhaust
Duct bracket
3
1
Replace
2
2
Replace
Water pump
Water Pipe - Remove and Inspect
Removal sequence
1 Water pipe, Bolt, Washer, O-ring 6 Water pipe, Coupling, Bolt, Washer, O-ring
2 Water pipe, Coupling, Bolt, Stud, Nut, O-ring 7 Water pipe, Bolt, Washer, O-ring
3 Water pipe, O-ring 8 Water pipe, Bolt, Washer, O-ring
4 Water pipe, Bolt, Washer, O-ring 9 Water pipe, U-bolt, Bolt, Nut, Washer, O-ring
5 Water pipe, Bolt, Washer, O-ring
11-4 99089-40100
2. Cooling System - Disassemble, Inspect, and Assemble

2.1 Water Pump - Disassemble and Inspect
Flaking, wear
Key groove deformed wear
Rotation
Replace
9
10 1
6
5 7
4 8
Replace
3
10
2 Corrosion, crack, damage
Replace
Replace
Corrosion, contacting mark
Corrosion, crack, damage
Replace
Water Pump - Disassemble and Inspect

1 Pump gear, Key, Nut, Lock washer 6 Ball bearing, snap ring
2 Flange, Bolt, Washer, O-ring 7 Spacer
3 Pump case 8 Ball bearing
4 Impeller, Nut, Lock washer 9 Shaft, Oil seal
5 Unit seal 10 Pump body, Bolt, Washer, O-ring
99089-40100
11-5
(1) Pump Assembled to Engine - Inspect

Touch the drain port at the center of the pump case bottom
with fingers.
If water is oozing out, the unit seal is defective, and if oil is
oozing out, the oil seal is defective.
Oil seal
Unit seal
Water Pump Mounted on Engine - Inspect

(2) Impeller - Remove
The impeller tightening nut may be right-hand or left-hand
thread. When loosening it, pay attention to its thread direc-
tion.
Seen from the engine front, the right-side impeller tighten-
ing nut on low-temperature system water pump has a right-
hand thread.
Low-temperature
Seen from the engine front, the left-side impeller tighten- High-temperature system
ing nut on high-temperature system water pump has a left- system water pump
water pump (Seen from the engine front)
hand thread with a v-groove marking on the nut periphery
High-Temperature System Water Pump and Low-
and right-hand thread without the marking.
temperature System Water Pump
Impeller
Washer
Impeller tightening nut
(Left-hand thread)
V groove for left-hand

screw identification
Shaft
V-groove Marking on the Impeller Tightening Nut to

Show the Left-hand Thread
(3) Water pump Shaft - Remove
When removing the impeller from water pump shaft,

be careful not to damage the water pump shaft and
impeller.
Remove the snap ring of rear bearing, push or tap the water
pump shaft lightly with a press or soft-headed hammer, then
take out the water pump shaft with the bearing and spacer as
a set to the gear side.
11-6 99089-40100
2.1.1 Water Pump - Inspect

Measure the water pump bearing housing with a cylinder
gauge.
If the wear is excessive, replace the shaft or body with a
new one.
Measurement item Nominal value Standard value Limit value
ø90 mm 89.994 to 90.013 mm
Body bearing housing inside diameter -
[3.54 in.] [3.5431 to 3.5438 in.]
ø90 mm 89.985 to 90.000 mm
[3.54 in.] [3.5427 to 3.5433 in.]
-0.006 to 0.028 mm 0.05 mm
[-0.0002 to 0.0011 in.] [0.0020 in.]
ø40 mm 39.988 to 40.000 mm
[1.57 in.] [1.5743 to 1.5748 in.]
ø40 mm 40.002 to 40.018 mm
Shaft bearing fitting-position diameter -
[1.57 in.] [1.5749 to 1.5755 in.]
-0.030 to -0.002 mm 0.05 mm
[-0.0012 to -0.0001 in.] [0.0020 in.]
Note: Minus (-) indicates the interference amount in diameter.
99089-40100
11-7
2.1.2 Water Pump - Assemble
Apply ThreeBond 1102

or equivalent to outer
circumference of unit 392 N·m {40 kgf·m}
Pay attention not to seal cartridge. [289 lbf·ft]
damage the unit seal Apply MOLY LG grease
sliding face. No.2 (manufactured by
Sumiko Lubricant Co.
Ltd.) or equivalent.
Apply LLC to outer
Apply ThreeBond 1215 circumference of
or equivalent to unit seal cup gasket.
washer both faces.
Bend washer
ø40 mm
[1.58 in.]
196N·m
{20kgf·m}
[145 lbf·ft] ø90 mm
[3.54 in.]
Right-hand
screw spec ø40 mm
[1.58 in.]
ø90 mm
[3.54 in.]
Clearance in diameter
0.75 to 0.86 mm
[0.0295 to 0.0339 in.]
Thick washer Left-hand

screw spec Apply engine oil to oil seal lip.
Water Pump - Assemble
11-8 99089-40100
2.2 Thermostat - Disassemble and Inspect

(with two thermostats spec.)
1
1
Replace
5
Replace
Thermostat - Disassemble and Inspect

1 Thermostat cover, Bolt, Washer, Plug 3 Seal
2 Thermostat 4 Plate, Bolt, Washer, Guide
5 Thermostat case, O-ring
99089-40100
11-9
2.2.1 Thermostat Working Temperature - Inspect
Be careful of hot water and flames.

You may get burned or cause a fire.
Immerse the thermostat in a container filled with water.

Heat the water while measuring water temperature. Record
the temperature at which the valve start to open, and at
which the valve lift becomes to the standard value. Replace
the thermostat if a deviation from the standard temperature
Thermostat - Inspect
is significant.
Note: Stir the water to maintain even temperatures during the
test.
Standard value
Identification
Thermostat part number Temperature at which Temperature at which valve lift becomes
mark
valve starts to open 27 mm [1.07 in.]
41046-22301 65°C [149°F] 63 to 67°C [145 to 153°F] 75°C [167°F]
41046-23401 71°C [160°F] 69 to 73°C [156 to 163°F] 81°C [178°F]
11-10 99089-40100
2.2.2 Thermostat - Assemble

Note:(a) Apply ThreeBond 1215 or equivalent to the seal periphery when the seal is replaced with a new one.
(b) Be sure to install the seal in the correct orientation.
Apply ThreeBond 1215 or

equivalent to seal
outer circumference.
Thermostat - Assemble
Apply ThreeBond 1215 or

equivalent to seal
outer circumference.
Thermostat with Guide - Assemble
99089-40100
11-11
1. Inlet and Exhaust Systems - Remove and Inspect ............................................. 12-3
1.1 Inlet System - Remove and Inspect........................................................................................ 12-3
1.2 Exhaust System - Remove and Inspect.................................................................................. 12-4
1.3 Exhaust Insulator - Remove and Inspect................................................................................ 12-7
2. Inlet and Exhaust Systems - Disassemble, Inspect, and Assemble ................. 12-8
2.1 Pre-cleaner - Disassemble and Inspect.................................................................................. 12-8
2.2 Paper Type Air Cleaner - Disassemble and Inspect............................................................. 12-10
2.3 Air Cooler - Disassemble and Inspect .................................................................................. 12-11
3. Inlet and Exhaust Systems - Install.................................................................... 12-13
3.1 Exhaust System - Install ....................................................................................................... 12-13
99089-40100
12-1
1. Inlet and Exhaust Systems - Remove and Inspect

1.1 Inlet System - Remove and Inspect
Replace
11
9 Replace
10
Replace 9 10
7 10
Replace 8
Replace
12
Replace
7
5 13
6
4 5
3 6 7 13
Replace
12
5 6
3 1 4 12 Replace Crankcase
3
2
1 12
6 13
1 Replace
Replace
2 Replace
Turbocharger 5 5
6
3 4
3
6 4
3
5
1
3 2
1
3
1 Replace
Replace
2
Turbocharger
Inlet System - Remove and Inspect

Removal sequence
1 Bellows, Bolt, Washer, Nut, O-ring 8 Air pipe, O-ring
2 Connector, Bolt, Washer, O-ring 9 Flange, Bolt, Washer, O-ring
3 Bracket, U-bolt, Bolt, Nut, Washer 10 Upper duct (approx. 76 kg [167.6 lb.]), Bolt, Washer,
4 Stay, Bolt, Nut, Washer Packing
5 Inlet pipe, Bolt, Washer, O-ring 11 Duct end cover, Gasket, Bolt, Washer
6 Inlet duct, Bracket, Bolt, Washer, O-ring 12 Air cooler assembly (approx. 240 kg [529.1 lb.])
7 Upper duct, Gasket, Bolt, Washer, Packing Washer, Packing
13 Lower duct (approx. 47 kg [103.6 lb.]), Bolt, Washer
99089-40100
12-3
1.2 Exhaust System - Remove and Inspect
1
1 3
A
E A
1 2
4
1 4
1 4
D C
3
1 4
1
4 4 4
1 4 4
2
4
4
3
8
3 B
5
5 2
10
5
6 4
4 C
7 5 11 E
5 7
7 10
7
5
6 5
5
4
4 5
5
4
6
6 3
F 2 4 6
4
6
6
9 6
F 9
8
D 8
CRANKCASE
CRANKCASE B
8
13 8
8
FORWARD
10
8
8 12 10
8 12
Exhaust System - Remove and Inspect

Removal sequence
1 Bolt, washer, Upper bracket, Lower bracket 8 Bolt, Washer, Bracket, Gasket
2 V-clamp 9 Bolt, Washer
3 Turbocharger (approx 90 kg [198.4 lb.]) 10 Bolt, Washer, Exhaust duct (approx. 185 kg [407.9 lb.]),
4 Bolt, Washer, Spacer, Gasket Lagging
5 Bolt, Washer, Nut, Bracket 11 Plug
6 Bolt, Washer, Nut, Bracket 12 Bolt, Washer
7 Bolt, Washer, Bracket 13 Bracket
12-4 99089-40100
(2 Left Side)
24
24
21
22 24 25
23
22
21
21
23
20
19 Replace
23
15 22 Replace
11 12
17 18 20
10
Replace 13 16 Replace 9
15 20 8
15 7
13 6
14 4 11
5
16 4 11
13 4
Replace
14
16 3
Replace 5 Replace
Replace Replace 2 5
14
Replace
Turbocharger 2 3 8
2 3
13
Replace 1 Replace
1
1 Cylinder head
Turbocharger
Replace all gaskets at
the cylinder head outlet.
Exhaust System - Remove and Inspect (left side)

Removal sequence
1 Exhaust pipe, Bolt, Nut, Washer, Gasket 14 Bellows, Bolt, Nut, Washer, Gasket
2 Bellows, Bolt, Nut, Washer, Gasket 15 Exhaust pipe, Bolt, Nut, Washer, Gasket
6 Exhaust pipe, Bolt, Nut, Washer, Gasket 19 Exhaust pipe, Bolt, Nut, Washer, Gasket
7 Bellows, Bolt, Nut, Washer, Gasket 20 Bellows, Bolt, Nut, Washer, Gasket
12 Exhaust pipe, Nut, Washer, Gasket 25 Exhaust pipe, Nut, Washer, Gasket
13 Exhaust pipe, Bolt, Nut, Washer, Gasket
99089-40100
12-5
(2 Right Side)
26
25
24
23 26
21 22
20
Replace
19
18
Replace
26 14
Replace
15 17
Replace 13
16
12 14
15 11
Replace
10
16 9
Replace 16 2 14
16
Turbocharger Replace 14
2 2
2 Replace
8
1 1
Replace
67
5
4 Cylinder head
Turbocharger 3
Replace all gaskets at
Replace the cylinder head outlet.
1
Exhaust System - Remove and Inspect (right side)

Removal sequence
1 Exhaust pipe, Bolt, Nut, Washer, Gasket 14 Exhaust pipe, Nut, Washer, Gasket
3 Exhaust pipe, Bolt, Nut, Washer, Gasket 16 Bellows, Bracket, Bolt, Nut, Washer, Gasket
13 Bellows, Bolt, Nut, Washer, Gasket 26 Exhaust pipe, Nut, Washer, Gasket
12-6 99089-40100
1.3 Exhaust Insulator - Remove and Inspect
3
4
2
6
6
2 6
8
9 7
10 (S16U)
Exhaust Insulator - Remove and Inspect

Removal sequence
1 Insulator, Bolt, Washer 6 Insulator, Bracket, Bolt, Washer
2 Insulator, Bolt, Washer 7 Insulator, Bolt, Washer
3 Insulator, Bolt, Washer 8 Bracket, Bolt, Washer
99089-40100
12-7
2. Inlet and Exhaust Systems - Disassemble, Inspect, and Assemble

2.1 Pre-cleaner - Disassemble and Inspect
Turbocharger
4
1
Pre-cleaner - Disassemble and Inspect

1 Bolt, Nut, Washer 4 Air cleaner or Pre cleaner
2 Cover 5 Cover
3 Silencer assembly
12-8 99089-40100
2.1.1 Pre-cleaner - Clean and Replace
Be sure to stop the engine, then remove the air

cleaner. Cover the inlet ports of engine and air
cleaner, and then proceed to the maintenance job.
The pre-cleaner attached to the turbocharger silencer keeps

the engine in a good condition by removing dust in the inlet tral)
(Neu
air. Use the silencer always in a clean condition.
(1) Remove the pre-cleaner from the silencer, and hand-
wash the pre-cleaner using a neutral detergent. Water
(2) Rinse with freshwater. (Wash) (Rinse)
(3) Dry the pre-cleaner well, and check the pre-cleaner for
damages such as break. Install
(4) If any defect is found, replace the pre-cleaner with a (Dry)

new one.
Pre-cleaner - Clean
(5) Install the pre-cleaner to the silencer after cleaning,
inspection or replacement of the pre-cleaner.
99089-40100
12-9
2.2 Paper Type Air Cleaner - Disassemble and Inspect
Air cleaner
element Body
When using compressed air, wear safety goggles, a
hard hat, gloves and other necessary protective gear.
Works without wearing proper protective gears may Wing nut
result in serious injury.
Do not conduct a maintenance job of the air cleaner
during operation. if the engine intakes dust, the engine
life is shortened by rapid wear of each part. Do not tap
or tap with the element.
Air Cleaner Element - Remove
Replace the element with a new one, if it shows

defects such as break, pin hole or worn area, or the
red signal of air cleaner indicator is displayed immedi-
ately after the element cleaning.
(1) remove the air cleaner cap or wing nut.

(2) Pull out the air cleaner element from the body.
(3) Blow compressed air of 0.69 MPa {7 kgf/cm2} [100
psi] or lower to the inside to remove dust and dirt.
(4) Blow compressed air to outside from a distance to pre-
Air Cleaner Element - Clean
liminary remove dust.
Then blow air from inside to outside along the mesh.
Then blow air to outside an inside again.
(5) Place an electric valve inside of the element to check
damage, pin hole or worn area after the cleaning.
(6) If any defect is found, replace the air cleaner element
with a new one.
(7) Assemble the air cleaner element after the cleaning,
inspection or replacement.
Air cleaner Element - Inspect

Rest the air cleaner indicator if it shows the red signal.
Signal
Reset button
Air Cleaner Indicator
12-10 99089-40100
2.3 Air Cooler - Disassemble and Inspect
Replace
2
Replace
1
2
1
3
Replace
Air Cooler - Disassemble and Inspect

1 Connector, Gasket, O-ring 3 Air cooler case
2 Air cooler element, Plate, Gasket
99089-40100
12-11
2.3.1 Air Cooler - Clean and Inspect

(1) Cleaning method of air cooler
Replace with a new one if significant corrosion or crack is
found in the inspection and cleaning described below.
(a)Apply compressed air (at a pressure of 0.29 to 0.49
MPa {3 to 5 kgf/cm2} [42 to 71 psi] or less) through
the air cooler in the opposite direction to the normal air
flow to remove the accumulation of dust and dirt.
Then, inspect for corrosion and cracks.
(b)If the contamination is significant, blow steam (hot
Air Cooler - Clean
water and compressed air at a temperature of 150°C or
below) to remove the deposit, then check corrosion
and crack.
(c)Clean the inside of tubes of tube type cooler using a
nylon brush.
(d)Apply chemical cleaning to the inside of fresh- and
sea-water pipes.
Note: Use a cleaning specialist with much experience for the
chemical cleaning as it may cause a serious damage to
the device without proper treatment.
(2) Air cooler - Check for Leak Air Cooler - Check for Leak
Immerse the air cooler in water. In this condition, blow
compressed air (at a pressure of 0.4 MPa {4 kgf/cm2} [57
psi]) to the coolant passage to check for air leak. Replace
the part if it shows leak.
12-12 99089-40100
3. Inlet and Exhaust Systems - Install

To install, follow the removal sequence in reverse. (See the illustration for disassembly.)
Thoroughly clean and dry the inlet and exhaust passages.
3.1 Exhaust System - Install
(LH)
Turbocharger
Cylinder head
Turbocharger
Exhaust System - Install (Left Side)
Note: Install the exhaust insulator after installing the exhaust system if the specification of the customer requires the exhaust in-
sulator.
99089-40100
12-13
(Right Bank)
Turbocharger
Turbocharger Cylinder head
Exhaust System - Install (Right Side)
Note: Install the exhaust insulator after installing the exhaust system if the specification of the customer requires the exhaust in-
sulator.
12-14 99089-40100
1. Air Start System - Remove and Inspect............................................................... 13-3
1.1 Main Air Pipe - Remove and Inspect ...................................................................................... 13-3
1.2 Distributor Valve, Starting Valve, Air Pipe - Remove and Inspect .......................................... 13-4
2. Air Start System - Disassemble, Inspect and Assemble.................................... 13-5
2.1 Distributor Valve - Disassemble and Inspect .......................................................................... 13-5
2.2 Distributor Valve - Inspect....................................................................................................... 13-6
2.3 Distributor Valve - Assemble .................................................................................................. 13-7
2.4 Starting air blow-in timing diagram ......................................................................................... 13-8
2.5 Starting Valve - Disassemble and Inspect .............................................................................. 13-9
2.6 Starting Valve - Inspect......................................................................................................... 13-10
2.7 Starting Valve - Assemble .................................................................................................... 13-11
2.8 safety Valve - Disassemble and Inspect............................................................................... 13-12
2.9 Safety Valve - Inspect........................................................................................................... 13-13
2.10 Safety Valve - Assemble....................................................................................................... 13-14
2.11 Magnetic Valve - Disassemble and Inspect.......................................................................... 13-15
2.12 Air Strainer - Check .............................................................................................................. 13-15
2.13 Air Tank - Disassemble and Inspect ..................................................................................... 13-16
3. Air Start System - Install ..................................................................................... 13-17
3.1 Main Air Pipe - Install............................................................................................................ 13-17
3.2 Distributor Valve, Starting Valve, and Air Valve - Install ....................................................... 13-18
99089-40100
13-1
1. Air Start System - Remove and Inspect

1.1 Main Air Pipe - Remove and Inspect
3
1
3
6
6
Replace
6 5
1
5
5
2 1
Replace 4
Main Air Pipe - Remove and Inspect

Removal sequence
1 Main air pipe, Union bolt, Gasket, Clamp, Bolt, Washer 4 Air pipe, Union bolt, Gasket
2 Main air pipe, Union bolt, Gasket, Clamp, Bolt, Washer 5 Air pipe, Check valve, Elbow
3 Main air pipe, Connector 6 Check valve, Bracket, Bolt, Washer
99089-40100
13-3
1.2 Distributor Valve, Starting Valve, Air Pipe - Remove and Inspect
2
2
2
2
2
2
2
2 3
Replace 2 2
2
Replace
Replace
Replace Replace 2
4
2
Replace 2
2
1
1
2
1 2
1
Distributor Valve, Starting Valve, Air Pipe - Remove and Inspect
Removal sequence
1 Clamp, Spacer, Bolt, Washer 3 Starting valve, Gasket, Connector
2 Air pipe No. 1 to No. 8, Connector, Union bolt, Gasket 4 Distributor valve
13-4 99089-40100
2. Air Start System - Disassemble, Inspect and Assemble

2.1 Distributor Valve - Disassemble and Inspect
Bolt Fixing Type
Camshaft
Matching mark "2" stamp
7
6
Matching mark "2" stamp
4
5
2
7
1 3 Replace
6
Replace
Replace 5
Distributor Valve (Bolt Fixing Type) - Disassemble and Inspect

1 Cover, Bolt, Washer, Packing 5 Distributor cover, Packing, Bolt, Washer
2 Distributor valve, Bolt, Washer 6 Cover, Bolt, Washer, Packing
3 Distributor shaft, Key 7 Shaft, Bolt, Washer
4 Bushing
Note: The bolt 2 is a left-hand thread. Pay attention to the rotating direction to disassemble.
99089-40100
13-5
2.2 Distributor Valve - Inspect

2.2.1 Depth of Distributor Valve Hole - Measure
Measure the valve hole depth. Replace if the limit is
exceeded. Sealing face
Replace the distributor valve with a new one if the seal sur-
face shows significant wear or damage.
Nominal Limit
value value
Depth of distributor 17 mm 16.9 to 17.1 mm 17.5 mm
valve hole [0.67 in.] [0.665 to 0.673 in.] [0.689 in.]
Depth of Distributor Valve Hole - Measure

2.2.2 Clearance Between Distributor Shaft and Bush-
ing - Measure
Measure the shaft outside diameter and the bushing inside
diameter. Replace the bushing if the limit is exceeded.
Nominal Limit
value value
19.959 to
Shaft diame- ø20 mm
19.972 mm -
ter [0.79 in.]
[0.7858 to 0.7863 in.]
Bolt Bushing
ø20 mm 20.03 to 20.05 mm
fixing inside diame- - Clearance Between Distributor Shaft and Bushing -
[0.79 in.] [0.7886 to 0.7894 in.]
type ter Measure
0.2 mm
The clear- 0.058 to 0.091 mm
- [0.008
ance above [0.0023 to 0.0036 in.]
in.]
13-6 99089-40100
2.3 Distributor Valve - Assemble

Bolt Fixing Type
76.6N·m{7.8kgf·m}
[56.50 lbf·ft]
Apply engine oil.
Matching mark "2"

22 2
Distributor Valve - Assemble (Bolt Fixing Type)

Note: Align the shaft matching mark "2" to the distributor-shaft marching mark "2", then install the distributor case to the engine
body.
99089-40100
13-7
2.4 Starting air blow-in timing diagram

The starting air blow-in timing in the case of standard injection timing is shown below.
Fuel injection timing 16°BTDC
No.1 cylinder top (No.8)
7°
Air flow-in 128°

Overlap 45°
45° 38° No.6 cylinder top
90° 90°7°
(No. 3)
No.4 cylinder top 7° 90° 90°
(No.5) 7° 45°
38°
45° Direction of rotation
No.2 cylinder top (No.7)
Starting Air Blow-in Timing Diagram
(Crank Angle)
13-8 99089-40100
2.5 Starting Valve - Disassemble and Inspect
Seat face defect, wear
Replace
Replace
Fatigue, crack
5
Replace
2
Replace
Starting Valve - Disassemble and Inspect

1 Cap, Bolt, Washer, O-ring 4 Spring, Plate, Bolt, Washer
2 Body, O-ring 5 Valve, Gasket
3 Piston, Snap ring, Gasket
99089-40100
13-9
2.6 Starting Valve - Inspect

2.6.1 Valve Outside Diameter, Piston Diameter and
Valve Body Inside Diameter - Measure
Measure with a micro meter. Replace it with a new one if
the limit is exceeded.
Nominal Standard
value value
20.984 to
ø21 mm 20.993 mm
[0.83 in.] [0.8261 to
0.8265 in.]
21.000 to Valve Outside Diameter, Piston Diameter and Valve
Valve body housing ø21 mm 21.016 mm Body Inside Diameter - Measure
-
inside diameter [0.83 in.] [0.8268 to
0.8274 in.]
0.007 to
0.032 mm 0.1 mm
[0.0003 to [0.004 in.]
0.0013 in.]
29.984 to
ø30 mm 29.993 mm
Piston outside diameter -
[1.18 in.] [1.1805 to
1.1808 in.]
30.000 to
Valve body piston hous- ø30 mm 30.016 mm
-
ing inside diameter [1.18 in.] [1.1811 to
1.1817 in.]
0.007 to
0.032 mm 0.1 mm
[0.0003 to [0.004 in.]
0.0013 in.]
2.6.2 Free Length of Valve Spring - Measure

Measure with a micro meter. Replace it with a new one if
the limit is exceeded.
Nominal Limit
value value
77 mm 69.7 to 77.3 mm 65 mm
Free length
[3.03 in.] [2.744 to 3.043 in.] [2.56 in.]
Free Length of Valve Spring - Measure
13-10 99089-40100
2.7 Starting Valve - Assemble
0.5 mm [0.020 in.] at room temperature

or more clearance B
Apply grease to
valve sliding face.
57N·m{5.8kgf·m}
[42 lbf·ft]
A
Valve opening pressure
2
0.59MPa{6.0kgf/cm }
[85.57 psi]
Lapping: Check the full circle 29.4±1.96N·m

ࠉࠉࠉࠉࠉࠉand even contact of seat face {3.0±0.2kgf·m}
ࠉࠉࠉࠉࠉࠉwith marking past. [21.68±1.45lbf·ft] C
Starting Valve - Assemble

Note:(a) Push the valve rear end with a screw drive from position A, and make sure that the valve moves. Apply air presuure
from the position A, and check the valve opening pressure is 0.59 MPa {6.0 kgf/cm2} [85 psi] or below.
(b) Pay attention to the tightening of cap bolts which press the starting valve. The cap must not be slanted by uneven tight-
ening. Adjust the height difference of B and C in the illustration to be 0.5 mm [0.0197 in.] or less after tightening the
bolts.
(c) Check the clearance between the piston and snap ring to be 0.5 mm [0.0197 in.] or more in a room temperature after
assembling.
99089-40100
13-11
2.8 safety Valve - Disassemble and Inspect
Replace: Gasket

1
fatigue
safety Valve - Disassemble and Inspect

1 nut, Shim 3 Valve
2 Spring 4 Body, Bolt, Washer, Gasket
13-12 99089-40100
2.9 Safety Valve - Inspect

2.9.1 Valve Diameter and Body Inside Diameter -
Check
Measure the valve diameter and body inside diameter with a ø18mm [0.71 in.]
micro meter. Replace it with a new one if the limit is

exceeded.
If the seat surface of valve or body is worn significantly,
replace the part with a new one.
Measurement Nominal
item value
Valve outside ø18 mm 17.950 to 17.968 mm Valve Diameter and Body Inside Diameter - Check
-
diameter [0.71 in.] [0.7067 to 0.7074 in.]
Body inside ø18 mm 18.000 to 18.018 mm
-
diameter [0.71 in.] [0.7087 to 0.7094 in.]
The clearance 0.032 to 0.068 mm 0.1 mm
-
above [0.0013 to 0.0027 in.] [0.004 in.]
2.9.2 valve Spring - Check

Measure the free length of valve spring with a vernier car-
iper. Replace the spring with a new one if the limit is
exceeded.
Measurement Nominal
item value
110 mm 109.5 to 110.5 mm 105 mm
Free length
[4.33 in.] [4.311 to 4.350 in.] [4.13 in.]
valve Spring - Check
99089-40100
13-13
2.10 Safety Valve - Assemble
A
57N·m
{5.8kgf·m}
[42.04 lbf·ft]
294N·m
{30kgf·m}
[216.84 lbf·ft]
Lapping: Check the full circle

ࠉࠉࠉࠉࠉࠉand even contact of seat face
ࠉࠉࠉࠉࠉࠉwith marking blue.
B
Safety Valve - Assemble

Note:(a) Pay attention to the tightening of safety valve bolt.
The valve must not be slanted by uneven tightening.
Adjust the height difference of A and B in the illus-
tration to be 0.5 mm [0.0197 in.] or less after tight-
ening the bolts.
(b) Measure the valve opening pressure. Adjust the
pressure to be with in the standard by increasing or
decreasing the number of shims, if the value is out
of the standard.
Measure-
Nominal value Standard value
ment item
15.7 MPa 15.5 to 16.2 MPa
Valve open-
{160.1 kgf/cm2} {158.1 to 165.2 kgf/cm2}
ing pressure
[2277.1 psi] [2248.1 to 2349.6 psi]
13-14 99089-40100
2.11 Magnetic Valve - Disassemble and Inspect
Coil disconnection
Fatigue, crack
Fatigue, crack
Defect on valve seat face
Magnetic Valve - Disassemble and Inspect
2.12 Air Strainer - Check

2.12.1 Air filter - Drain water, and Element - Clean
Close the starting-valve handle of air tank, remove the plug,
and drain water. Remove the cap, then remove the element
from the cap. Clean the filter in light oil, blow compressed Air inlet Air outlet
air, then dry and install the filter.
Filter Cap
Spring
Packing Plug
Air strainer
99089-40100
13-15
2.13 Air Tank - Disassemble and Inspect
Water drain
Air pressure check:
3.0MPa{30kgf/cm2}
[435 psi]
Safety valeve
operation check:
Blow-out pressure
2
3.14MPa{32kgf/cm }
[455 psi]
Air Tank - Disassemble and Inspect

Note: When the air tank is replaced in the case of ship classification applied engine, use an air tank complies with the same clas-
sification.
2.13.1 Safety Valve Function - Check

Check the proper movement of safety valve at the specified
pressure.
Blow-out pressure
3.14 MPa {32.02 kgf/cm2} [455.42 psi]
13-16 99089-40100
3. Air Start System - Install

3.1 Main Air Pipe - Install
59±1N·m
{6.0±0.1kgf·m}
[43.52±0.74 lbf·ft]
44±5N·m{4.5±0.5kgf·m}
[32.45±3.69 lbf·ft]
Main Air Pipe - Install
99089-40100
13-17
3.2 Distributor Valve, Starting Valve, and Air Valve - Install
34±4N·m
{3.5±0.4kgf·m}
[25.08±2.95 lbf·ft]
Distributor Valve, Starting Valve, and Air Valve - Install
13-18 99089-40100
1. Engine - Adjust ...................................................................................................... 14-3
1.1 Valve Clearance - Check and Adjust ...................................................................................... 14-3
1.2 Both inlet and both exhaust valve heights by valve bridge - Adjust........................................ 14-4
1.3 Fuel Injection Timing - Inspect and Adjust.............................................................................. 14-7
1.4 Fuel System - Bleed Air ........................................................................................................ 14-10
2. No-Load Minimum Engine Speed (Idling) and No-Load Maximum Engine Speed - Check and
Adjust................................................................................................................................... 14-12
2.1 Woodward Governor, Ltd. make mechanical/hydraulic governor UG8 type (lever type)...... 14-12
2.2 Woodward Governor, Ltd. make mechanical/hydraulic governor UG8 type (dial type) ........ 14-13
2.3 Woodward Governor, Ltd. make mechanical/hydraulic governor UG8 type......................... 14-14
3. Test Operation ..................................................................................................... 14-15
3.1 Preparation of operation ....................................................................................................... 14-15
3.2 Test Operation ...................................................................................................................... 14-15
4. Performance Test ................................................................................................ 14-16
4.1 Engine Equipment Condition ................................................................................................ 14-16
4.2 Test Items and Purposes...................................................................................................... 14-16
4.3 Other Inspections ................................................................................................................. 14-16
4.4 Engine Output Adjustment.................................................................................................... 14-16
99089-40100
14-1
1. Engine - Adjust
1.1 Valve Clearance - Check and Adjust
The valve clearance should be inspected and adjusted when the engine is cold.
Knob
Mounting screw
Place the turning gear in the released position when-
ever start the engine.
Rocker cover
(1) Loosen the rocker cover setting screws and remove the
rocker covers of all cylinders.
Note: Prepare waste cloth or the like as the engine oil spills Rocker cover installation Rocker cover
when the rocker cover is removed. 18 ± 2 N・m {1.8 ± 0.2 kgf・m} Gasket
[13±1lbf・ft]
(2) Remove the lock pin of turning gear. And push the han-
Rocker Cover - Remove
dle to the arrow direction to place the turning gear in
the "Engaged" position.
(3) Turn the turning gear shaft with a socket and ratchet Ratchet handle
wrench when the gear is in the "Engaged" condition to
Socket
turn the crankshaft. Move the ratchet handle from lower
to upper position to turn the crankshaft in the forward
direction (counter-clockwise seen from the flywheel Handle
end). Turning
Gear shaft Engaged
Released
Released (
(starting)
(4) Check the inlet and exhaust valve clearances of the cyl-
Cylinder in TDP condition
inder referring to the alignment of flywheel punch mark (Crank angle)
and pointer which shows the TDC of two cylinders.
The cylinder which has valve clearances is in the com-
pression TDC condition. O
R1.R6
(Example) When the pointer is aligned with "R1·R6" S12U
S12U Clearance
damper punch mark, either No. R1 or No. R6 cylinder
in the right bank is at the compression TDC. Pointer
O
R1. R8
S16U Fly wheel punch line

Compression Top Dead Center - Check
99089-40100
14-3
1.2 Both inlet and both exhaust valve heights by valve bridge - Adjust
1.2.1 Valve Clearance - Inspect
Check the valve clearance after adjusting the front and rear
valve height of valve bridge.
(1) Inspection and adjustment sequence of valve clearance.
Inspect and adjust the valve clearances according to the
engine firing order and at the compression TDC of each
cylinder.
Measure-
Cylinder Number
ment item
R1-L1-R6-L6-R2-L2-R4-L4-R8-L8-R3-L3-R7-
Firing order
L7-R5-L5
(2) Insert the feeler gauge which has the same thickness to
the specified valve clearance between the rocker arm
and bridge cap of the appropriate cylinder.
Feeler
gauge
Standard
Measurement item
value
0.6 mm
Inlet valve
[0.024 in.]
Valve clearance
0.8 mm
Exhaust valve
[0.032 in.]
(3) Move the feeler gauge. The valve clearance is proper

when the movement feels mild restriction. Adjust the Valve Clearance - Inspect
valve clearance referring to the procedure in "Valve

Clearance - Adjust" when the feeler gauge can not be
inserted or the restriction is too tight.
14-4 99089-40100
If the clearance between the valve bridge and valve cotter is below the limit, the valve cotter may be displaced by
interfering. If the clearance is below the limit after adjusting the front/rear valve height with the valve bridge adjust-
ing screw, replace the most worn part among valve, valve cotter, upper retainer or valve bridge with a new one.

Valve bridge and 2.0 mm 1.0 mm
valve cotter clearance [0.079 in.] or more [0.039 in.] or more
Adjust the valve bridge screw to equalize the front/rear

valve heights before measuring the valve clearance. Valve clearance
Valve bridge
A clearance is made between the valve cotter and valve
bridge when the valve seat or other part is worn and the Valve cotter
heights of front/rear valves are not the same. This results in

an improper valve clearance measurement.
valve bridge and
valve cotter
Valve
Clearance Between Valve Bridge and Valve Cotter

(1) loosen the lock nut of valve-bridge adjusting screw, and
turn back the adjusting screw.
(2) Press the rocker arm by finger and slowly tighten the 10°further
tightening Adjusting
adjusting screw.
screw
(3) Turn the adjusting screw by approx. 10°when the tip of
Lock nut
adjusting screw contacts the valve-stem top face, then
Valve
fix the screw with the nut. Rocker arm Bridge
Valve stem
Front/rear Valve Height Adjustment By Valve Bridge

1.2.2 Valve Clearance - Adjust
(1) Loosen the lock nut of rocker-arm adjusting screw.
(2) Adjust the screw to feel a mild restriction of the feeler Adjusting screw
gauge. Lock nut
(3) Tighten the lock nut to fix the adjusting screw when the
clearance becomes the standard value.
Valve Clearance - Adjust
99089-40100
14-5
1.2.3 Rocker Room - Inspect

Rocker arm Piece
Inspection items Inspection item Adjusting screw
Rocker shaft bracket Looseness
Wear, oil hole clogging,
Rocker arm, valve bridge
piece looseness Valve bridge
Adjusting screw Damage on threads
Cylinder head Crack, damage, carbon deposit
Rocker shaft bracket

Rocker Room - Inspect
1.2.4 Rocker Cover - Install
Knob
(1) Install the rocker cover after the valve clearance adjust-
ment. Mounting screw
Note: Wipe off engine oil on rocker cover gasket and sealing
face if smeared. Rocker cover
(2) Adjust the rocker cover position to avoid the slanted
position of setting screw.
(3) Hand tighten the setting screw knob, then tighten to the Rocker cover installation Rocker cover
specified torque with a wrench. 18 ± 2 N・m {1.8 ± 0.2 kgf・m} Gasket
[13±1lbf・ft]
Rocker Cover - Install
1.2.5 Turning Gear - Release
Ratchet handle
Place the turning gear in the released position when- Socket

ever start the engine. Starting with the turning gear in
an engaged condition will result in a serious accident
Handle
to break the ring gear.
Turning
Be sure to return the turning gear handle to the released Gear shaft Engaged
position and insert the lock pin after finishing the vave Released
Released (
(starting)
clearance adjustment.
14-6 99089-40100
1.3 Fuel Injection Timing - Inspect and Adjust

1.3.1 Fuel Injection Timing and the Position of Cau-
tion Plate VALVE CLEARANCE㸦COLD㸧
ࣂࣝࣈࠉࢡࣜ࢔ࣛࣥࢫࠉ㸦࢚ࣥࢪࣥ෭᫬㸧
The fuel injection timing differs according to the output INLET 0.6mm EXHAUST0.8mm
࢖ࣥࣞࢵࢺ ࢚࢟ࢰ࣮ࢫࢺ
power, engine speed and specification. Confirm the fuel FIRING ORDER ╔ࠉⅆࠉ㡰ࠉᗎ
R1-L1-R6-L6-R2-L2-R4-L4
-R8-L8-R3-L3-R7-L7-R5-L5
injection timing of each engine with the caution plate FUEL INJECTION TIMING
⇞ ᩱ ᄇ ᑕ ᫬ ᮇ BTDC
attached on the R No.1 rocker cover.

For the adjusting procedures, refer to "Valve Clearance -
Inspect and Adjust" of "ENGINE BODY - ASSEMBLE ".
Caution Plate Position

(In the Case of Normal Rotation)
1.3.3 Injection Timing - Check
(1) Remove the cam room cover of the appropriate injec-
tion pump.
(2) Turn back the crankshaft to approx. 30°before compres-
sion TDC of the cylinder.
(3) See the inspection window of injection pump, and turn
slowly the crankshaft in the forward direction. Matching mark
(4) Stop the turning when the matching marks are aligned
in the plunger upward movement, and read the flywheel
stamp line.
Matching Marks on the Fuel Injection Pump
(5) This is the fuel injection starting position.
Flywheel Punch Mark and Matching Mark

(In the Case of Fuel Injection Timing 22°BTDC)
99089-40100
14-7
1.3.4 Injection Timing - Adjust

Adjust the fuel injection timing by adjusting the shims
installed below the fuel-injection-pump setting flange.
The shim thickness rage is from 0.5 mm [0.020 in.] to 2.0 mm [0.079 in.] for the adjustment. The fuel injection pump
will be damaged if the shim thickness is out of the shim thickness range.
(1) Check the shim thickness installed in the fuel injection
pump before adjustment. And consider the necessity of
injection timing adjustment.
Note: Store the shims as a set for each cylinder.
(2) Close the fuel in/out valves to shut off the fuel supply.
Note: Drain the fuel in the fuel pipe by air bleed valve if the
fuel is remained.
(3) Remove all the pipes connected to the fuel injection
pump.
(4) Loosen all the bolts fixing the fuel injection pump, and
Injection pump
raise the pump to make a clearance at the dowel pin. Fixing bolt
167±17N・m
(5) Adjust the shim thickness for the proper injection tim- {16.7±1.7kgf・m}
ing. >±12 lbt·ft]ࠉࠉ
Note:(a) Increase the shim thickness to retard the injection

timing, or reduce to advance.
(b) Code marks are stamped on the shims for the indi-
Shim
cation of thickness.
Mark punching
position
Injection Timing - Adjust
Fuel injection timing shift

Shim thick-
Ref. No.
ness
amount BTDC ATDC
(crank angle) Advanced Retarded
0.2mm angle angle
1 0.72°
[0.008 in.]
Shim thickness Shim thickness
0.3mm reduce increase
2 1.08°
[0.012 in.]
Injection TDC (Crank angle)
0.5mm
3 1.80° timing (TDC)
[0.020 in.]
Change of Injection Timing
14-8 99089-40100
(6) Tighten the fuel injection setting bolts to the specified

torque, and open the cam chamber cover of each cylin-
der.
(7) Turn the crankshaft and verify that the fuel-injection-
pump tappet roller contacts camshaft fuel cam lobe
without clearance.
Note: The change of fuel injection timing must be within
2°of crank angle when the timing is adjusted by the
sims.
If the adjustment of 2°or more of crankangle is re-
quired, replace the cam gear. Clearance
is not allowed.
Clearance Between Cam and Tappet - Inspect

(8) Install the pipes connected to the fuel injection pump
after adjusting the fuel injection timing.
Install the cam room cover.
(9) Check the fuel leak and engine oil leak after supplying
the fuel. Replace the caution plate on the rocker cover
to the new one showing the stamp of changed injection
timing.
99089-40100
14-9
1.4 Fuel System - Bleed Air
(a) Thoroughly wipe off fuel spilled out of the air vent
(Lock release)
plug to prevent a risk of fire. ࠉTurn ant-clockwise.
(b) After the air bleeding, be sure to lock the priming
pump cap securely. If loosely locked, it can cause
(Lock)
damage to the priming pump and result in fuel
(Priming) Keep pushing
leaks and a fire. ࠉMove forward and
Priming and backward. turn clockwise.
pump cap
If the all air vent plugs are tightened before locking the Operating procedure of priming pump
priming pump cap, pressure in the priming pump
resists the cap to return.
Air bleeding of the fuel system must be started from the
place closest to the fuel tank, from the fuel filter (wire mesh
element), fuel filter and then fuel supply pipe.
1.4.1 Fuel Filter (Wire Mesh Element Spec.) - Bleed

air
Bracket
If the air vent plug, threads of bracket, or sealing

washer is damaged, replace with a new one.
Air vent plug,
(1) Loosen the air vent plug of fuel filter by about 1.5 turns. Sealing washer
(2) Turn the priming pump cap counterclockwise and move
it back and forth.
(3) When fuel flowing from the vent holes no longer con-
tains air bubbles, tighten the air vent plugs. Fuel Filter (Wire Mesh Element Spec.) - Bleed Air
1.4.2 Fuel Filter (Center Bolt Type) - Bleed Air

Air vent plug, Air vent plug,
Sealing washer Sealing washer

washer is damaged, replace with a new one.
(1) Loosen the air vent plug of fuel filter by about 1.5 turns.
(2) Move the cap back and forth repeatedly.
(3) When fuel flowing from the vent holes no longer con-
tains air bubbles, tighten the air vent plugs.
Fuel Filter (Center Bolt Type) - Bleed Air
14-10 99089-40100
1.4.3 Fuel Filter (Cartridge Type) - Bleed Air

Right air vent plug,
Handle Sealing washer

washer is damaged, replace with a new one. Bracket
(1) Place the fuel filter handle to the L-OPEN, R-AIR

PURGE position, then loosen the air vent plug by 1.5 Left air vent plug,
turns. Sealing washer
(2) Move the priming pump cap back and forth. When fuel
Left fuel filter
flowing from the vent holes no longer contains air bub- Right fuel filter
bles, tighten the air vent plugs. Fuel Filter (Cartridge Type) - Bleed Air
(3) Place the fuel filter handle to the R-OPEN, L-AIR Normal position Left side replacing
PURGE position, then loosen the air vent plug by 1.5 Right side replacing position
position OPER ATION
(Only right-side
turns. (Only left-side ef
to
gh
n
pe
ts
top
N o r ma l
R-
L-
CL
OP SE
O
fuel filter allows
EN :
fuel flow.)
L
Ri
CL EN:
:R
fuel folter allows
Le
(4) Move the priming pump cap back and forth. When fuel
E:
ft
P
OS
ig
st en
L-O
ࠉ
ht
op
op
R-
fuel flow.)
flowing from the left vent hole no longer contains air ࠉ
ge
L-AI R PU
N: L ef t o pen
R-OPEN: Right open
bubbles, tighten the air vent plug.
L -OPE
IR PU
a ir p
(5) Return the handle to the OPERATION position.
R-A
ge ur
Fuel-Filter Changeover Cock Position

1.4.4 Fuel Main Pipe - Bleed Air
(a) Lock the priming pump cap before tighten the air
vent plug.
If the all air vent plugs are tightened before locking
the priming pump cap, pressure in the priming
pump resists the cap locking.
(b) Thoroughly wipe off fuel spilled out of the air vent
Air vent cock Fuel supply pipe
plug to prevent a fire.
(1) Loosen the air vent plug of fuel main pipe by approxi- Fuel Main Pipe - Bleed Air (1)
mately 1.5 turns to bleed air.
(2) Move the priming pump back and forth. When the fuel
flowing from the vent holes no longer contains air bub-
bles, lock the priming pump by turning the cap clock-
wise while pushing it down.
(3) Tighten the air vent plug of fuel main pipe.
Air vent cock Fuel supply pipe
Fuel Main Pipe - Bleed Air (2)
99089-40100
14-11
2. No-Load Minimum Engine Speed (Idling) and No-Load Maximum Engine Speed - Check
and Adjust
(a) The inspection and adjustment of no-load minimum speed and maximum speed should be conducted by the
designated service shops only, as the set bolt of every engine is sealed after the confirmation of output using
the test bench.
(b) After the governor parts are adjusted, all external stoppers must be sealed. These seals, in case of engine trou-
ble, are very important, as they are one of key factors for the claim judgment. Be sure to seal all the specified
sections.
(c) Taking into consideration of the engine overrun, be ready to operate the engine stop lever manually when
inspecting and adjusting.
Prior to the inspection and adjustment, conduct a warm-up operation until the coolant and oil temperatures rise up to 70°C
[158°F] or higher.
Note: The type of governor varies according to the specification. Refer to "Governor Operation Manual" (separate volume) for
the detail including inspection and adjustment shown below.
2.1 Woodward Governor, Ltd. make mechanical/hydraulic governor UG8 type (lever type)
Refer to "Governor Operation Manual" (separate volume) fo the inspection and adjustment of UG8-type (lever-type), UG-
Actuator and UG-25+ governors.
14-12 99089-40100
2.2 Woodward Governor, Ltd. make mechanical/hydraulic governor UG8 type (dial type)
(1) Speed set dial (speed setting)
0
(a)Referring to the speed set indicator turn the speed set 9 1
dial clockwise to the specified speed setting.
8 2
Note:(a) The speed set dial can turn approx. 20 turns in total.
(b) The speed set indicator pointer indicate 1 when the 7 3
speed set dial is turned one turn.
6 4
(c) The speed set indiator shows 0 at the low-idling po-
5
sition and 11 at approx. 1000min-1.
Speed Set Dial

(2) Droop set dial
(speed droop) 50
40 60
(a)When the engine is operated independently set to the 0
30 70
position.
(b)When the engine is operated in parallel, adjust to the 20 80
minimum value at which the satisfactory load sharing 10 90
is available. 0 100
Droop Set Dial

(3) Hunting - Adjust
(a)Run the engine under no load.
(b)Loosen the nut of speed set indicator pointer and move Nut
the pointer to the upper limit.
(c)Remove the plug and loosen the needle valve by 3 to 5 Adjusting
indicator
turns with a flat-tip driver.
needle
indicator
needle
Place the driver tip in the shallow groove of needle
valve. Plug
Hunting (Dial Type) - Adjust
(d)Seal each set bolt.
(e)Turn the pointer to the lowest limit.
(f)Screw in the needle valve until the hunting stops.
Fully closed
(g)Further screw in the needle valve from the hunting
Needle
stop position to the fully closed position. Then turn valve Hunting stop
Needle
back the valve to the hunting stop position. valve
Note: Normally the turn back amount is 1/2 to 1 turn.
(h)When the hunting does not stop after the procedure
above, raise the pointer position by 2 scales and re-
adjust the needle valve. 1/2 to 1 turn.
Needle Valve (Dial Type) - Adjust
99089-40100
14-13
2.3 Woodward Governor, Ltd. make mechanical/hydraulic governor UG8 type

(a)Run the engine under no load.
(b)Loosen the nut of speed set indicator pointer and move
the pointer to the upper limit. Nut
(c)Remove the plug and loosen the needle valve by 3 to 5
turns with a flat-tip driver. Adjusting
indicator
needle
indicator
Place the driver tip in the shallow groove of needle
needle
valve.
Plug
Hunting (Lever Type) - Adjust
(d)Seal each set bolt.
(e)Turn the pointer to the lowest limit.
(f)Screw in the needle valve until the hunting stops. Fully closed
Needle
(g)Further screw in the needle valve from the hunting
valve Hunting stop
stop position to the fully closed position. Then turn Needle
valve
back the valve to the hunting stop position.
Note: Normally the turn back amount is 1/2 to 1 turn.
(h)When the hunting does not stop after the procedure
above, raise the pointer position by 2 scales and re- 1/2 to 1 turn.
adjust the needle valve.
Needle Valve (Lever Type) - Adjust
14-14 99089-40100
3. Test Operation
3.1 Preparation of operation
(1) Various Valve Open or Closed Conditions Relating to
Pipings - Check
Check the closed/open conditions of valves, plugs and
cocks below.
Fuel supply valve Open

Each cooling water drain cock and plug Close
Oil drain plug Close
Air supply valve (air tank) Open
(2) Looseness of Wires - Check
Check the disconnection of cords at each device terminals in
the electric system.
3.2 Test Operation
Test run the engine following the procedure below.
Note: Refer to the Operation and Maintenance Manual for
the procedure of Starting, Warming-up operation, Op-
eration, Stopping, Emergency stopping and Inspection
after stopping.
(1) Engine- Lubricate
Conduct the procedure below to apply engine oil to the
engine each part.
(a)Pull the manual stop lever to "STOP" direction, and
keep the fuel injection pump in a no-injection condi-
tion.
(b)Crank the engine for approx. 10 seconds three times by
the starting air. (Allow 1 minute interval.)
(c)Verify the rise of engine oil pressure in this procedure.
(2) Engine starting
(3) Low-idle running 10 minutes
(4) Engine stop 30 minutes
(a)Check the leak of fuel, engine oil, cooling water and
exhaust gas while the engine is stopped. Repair the
leak completely if found.
(b)Check the oil and cooling water levels after 30 min-
utes. Refill to the specification if necessary.
(5) Low-idle running 5 minutes
(6) Rated-speed no-load running 5 minute
(7) 25% load running (note: 1) 30 minutes
(10)100% load running (note: 1) 60 minutes
Note: In the case of marine propulsion engine, apply load on
the third power curve (propeller curve).
(11)Engine stop
99089-40100
14-15
4. Performance Test
The following describes the procedures specified in "Earth
moving machinery - Engines - Part 1: Test code of net
power (JIS D0006-1)" and "Earth moving machinery -
Engines - Part 2: Standard format of specifications and test-
ing methods of diesel engines (JIS D0006-2)." Other test
items may be required in some applications. All test results
should be evaluated comprehensively in order to determine
the engine performance.
4.1 Engine Equipment Condition
The engine must be equipped with standard auxiliary
devices such as an air cleaner.
4.2 Test Items and Purposes

4.2.1 Operation load test
Conduct this test to evaluate the engine output, torque, fuel
consumption rate and governor performance under various
load conditions.
4.2.2 Continuous load test
Operate the engine continuously for 10 hours at 90% load
(continuous load application) of nominal net brake power
while the engine speed is maintained at revolutions corre-
sponding to the nominal brake power. In this test, evaluate
the fuel consumption rate and operating condition, and con-
firm that the engine is capable of continuous operation.
4.2.3 No-load minimum engine speed test
Conduct this test to confirm that the engine can operate sta-
bly at the specified no-load minimum engine speed.
4.3 Other Inspections

Check for gas, coolant and oil leaks; abnormal odors; and
hunting. Make adjustments as needed.
4.4 Engine Output Adjustment

Diesel engine output is affected by atmospheric pressure,
temperature and humidity. Therefore, correction calcula-
tions must be performed to obtain the value of engine output
under the standard atmospheric conditions.
4.4.1 Standard atmospheric conditions
Reference temperature 298 K (25ºC [77ºF] )
Atmospheric total pressure: 100 kPa (750 mmHg)
Reference atmospheric dry pressure: 99 kPa (743 mmHg)
14-16 99089-40100
4.4.2 Calculation of corrected power

Multiply the measured brake power or torque by the calcu-
lated diesel engine correction factor to obtain a corrected
value. If the applicable range of the correction formula is
exceeded, indicate the corrected values and record the test
conditions on the test record.
99089-40100
14-17
SUPPLEMENT 1 GAS CHARGING MANUAL
1. Gas Charge Method ·······························································································Supplement 1- 2

1.1 Jig ································································································································· Supplement 1- 2
1.2 Releasing Hydraulic Pressure······················································································ Supplement 1- 2
1.3 Charging Nitrogen Gas ································································································ Supplement 1- 3
1.4 Removing Charging Valve···························································································· Supplement 1- 6
Supplement 1 – 1
1. Gas charge method

1.1 Jigs
zCharging valve zHose zPressure zNitrogen gas

reducing valve cylinder
(The proper cylinder

should be prepared.)
41091-05800 VALVE, CHARGING
Charging valve: structure, notes 41091-05900 VALVE, PRESSURE REDUCING
Joint
Top handle (for pushing core)
Gasket B Union nut
Side handle (for Gasket A Seal washer
pressure relief)
Installed port Pressure gage
of hose
Union nut
Joint A TV8 thread
Joint A Joint B
Joint B 5/8-18UNF thread
*The joint B should be used after removed.

1.2 Releasing hydraulic pressure
In case that the accumulator is installed to the fuel piping, it should be checked after the fuel reciprocating
valve is tightened and the air bleeder cock of fuel main pipe is released slowly to release the hydraulic pressure
to the accumulator slowly till it becomes to air pressure.
In case that the accumulator is removed from the fuel piping to be checked, it should be removed after the fuel
reciprocating valve is tightened and the air bleeder cock of fuel main pipe is released slowly to release the
hydraulic pressure to the accumulator slowly till it becomes to air pressure.
Note: If the hydraulic pressure is released rapidly, the bladder may be expanded rapidly and be broken.
Supplement 1 - 2
1.3 Charging Nitrogen gas

(1) Connecting accumulator to nitrogen gas cylinder
(a) Connecting hose to charging valve
The hose should be connected to the charging valve. As for the part No. 41091-05800, the hose has been connected to
the charging valve.
(b) Releasing charging valve

The top handle of charging valve should be turned to counter-clockwise till it is stopped. The side handle to release the
pressure should be turned to counter-clockwise to release the pressure to air.
Charging valve
Top handle
Pressure gage Side handle 2. The handle should be released.

Union nut
Joint A
1. The hose should be
connected to the
accumulator. Valve guard
3. The caps should be removed.
Cap
4. The charging valve
should be connected
to the accumulator.
Hose
5. The pressure reducing

Accumulator valve should be connected
to the cylinder.
Pressure reducing valve
6. The hose should be

connected to the pressure
reducing valve.
Nitrogen gas cylinder
(c) Removing caps

The valve guard and the cap should be removed from the gas valve of accumulator.
(d) Connecting charging valve to accumulator

The joint A of charging valve should be tightened with hand and screwed to be stopped at the top of gas valve for the
accumulator. The pressure gage of charging valve should be installed to be seen and fixed by tightening the union nut. If
interference between the charging valve and the parts around it is caused when the charging valve is fixed to the
accumulator, the connecting operation should be performed after the accumulator is removed from the fuel piping.
Fixing join A Fixing union nut
(The photographed accumulator is different

from Part No. 41061-08900)
Supplement 1 - 3
(e) Connecting pressure reducing valve to nitrogen gas cylinder

The pressure reducing valve should be connected to the nitrogen gas cylinder. The pressure reducing valve
should be connected between the nitrogen gas cylinder and the hose to perform gas charging in safe and easy
condition.
Note: The thread to connect the nitrogen gas cylinder is decided by JIS standard as followings: W22 external
thread, W23 internal thread and W30 external thread. The pressure reducing valve (41091-05900) is able to
be connected to W22 directly. The A type adapter belonged to 41091-05800 should be used for W23, and
the B type adapter should be used for W30.
A type adapter B type adapter

Cylinder side
Cylinder side
(accessory for 41091-05800)
(f) Connecting hose to pressure reducing valve

The hose should be connected to the pressure reducing valve.
(2) Charging nitrogen gas

(a) Opening valve of nitrogen gas cylinder
The handle of pressure reducing valve should be
turned to counter-clockwise to close the pressure
reducing valve and to shut the passage to the
accumulator.
The cock of nitrogen gas cylinder should be opened.
Check that the pressure gage for the primary
pressure (pressure at the cylinder side) of reducing
valve is the internal pressure of cylinder and the
pressure gage for the secondary pressure (pressure at
the accumulator side) is the air pressure.
(b) Opening pressure reducing valve

The handle of pressure reducing valve should be
turned to clockwise to open the valve gradually.
Pressure rise of pressure reducing valve should be
stopped after the gas is checked to be released from
the side handle of charging valve.
Supplement 1 - 4
(c) Inflowing gas to accumulator

The side handle of charging valve should be turned
to clockwise till it is stopped and tightened up. (The
pressure inside of charging valve becomes 0.5MPa
[G] nearly.)
The top handle of charging valve should be turned to
clockwise till it is stopped. At this moment, the
pressure inside of charging valve becomes lowering
from 0.5MPa [G] because the nitrogen gas inflows
to the accumulator. Therefore the movement of hand
for the pressure gage shows the position to stop the
handle.
Note: If the top handle of charging valve is turned to (The photographed
clockwise too much, the core is broken. accumulator is different from
Part No. 41061-08900)
(d) Adjusting quantity of charging gas

+0
(pressure: 0.35 −0.02 MPa)
The pressure reducing valve should be opened more
to charge nitrogen gas into the accumulator
gradually. The pressure reducing valve should be
closed sometimes to see the value of pressure gage
when the hand of gage is stabilized, and the gas
should be charged until the pressure becomes to the
specified pressure. (It takes some time to stabilize
the gas pressure after the pressure reducing valve is
closed.)
If the charging pressure becomes higher, the gas
should be adjusted to be released gradually by the
side handle of charging valve turned to
counter-clockwise gradually.
(e) Closing valve of nitrogen gas cylinder

The pressure reducing valve and the nitrogen gas
cylinder should be closed surely after nitrogen gas is
charged to specified pressure.
Supplement 1 - 5
1.4 Removing charging valve

(1) Checking gas leakage, installing caps
(a) Removing charging valve
The top handle of charging valve should be turned to
counter-clockwise until it is stopped.
The side handle should be turned to
counter-clockwise to release the gas pressure left in
the hose.
The union nut of charging valve should be loosened
and the joint A should be turned to remove the
charging valve from the accumulator.
(The photographed
accumulator is different from
Part No. 41061-08900)
(b) Checking gas leakage and installing caps

The gas valve of accumulator should be checked the
gas leakage by soapy water or the leak checker.
After the check, the caps should be installed.
(The photographed
accumulator is different from
Part No. 41061-08900)
Supplement 1 - 6
SUPPLEMENT 2
ENGINE INSPECTION RECORD SHEET (SU SERIES)
No. 1 Measurement of Cylinder Liner Bore Diameter
No. 2 Measurement of Anti-polish-Ring spec. Cylinder Liner Inner Diameter

Measurement of Anti-polish-Ring Inside and Outside Diameter
No. 3 Measurement of Valve Guide Inside Diameter

and Valve Stem Diameter
No. 4 Measurement of Piston Bushing Inside Diameter

and Piston Pin Diameter
No. 5 Measurement of Connecting Rod Bearing Inside Diameter

and Crankshaft, Crankpin Diameters
No. 6 Measurement of Rocker Bushing Inside Diameter

and Rocker Shaft Diameter
No. 7 Measurement of Piston Pin Bore Diameter

and Piston Pin Diameter
No. 8 Measurement of Valve Clearance
No. 9 Measurement of Injection Start Pressure of Fuel Injection Nozzle
No. 10 Measurement of Camshaft Bushing Inside Diameter

and Camshaft Journal Diameter (Right Side)
No.11 Measurement of Crankshaft End Play
No.12 Measurement of Crankshaft Deflection

INSPECTION RECORD SHEET No.1
SU
Engine Model
Company DATE
Serial No.
Inspection
Point
Measurement of Cylinder Liner Bore Diameter UNIT mm[in.]
Measuring Locations Standard

Nominal
200 [2.17]
Standard Limit
55
Upper Transverse to piston pin Value

400 [7.87]
Parallel to piston ring

240.000
[15.75]
Middle Cylinder Liner φ240 to 240.046 240.400

Bore Diameter [9.45] [9.4488 to [9.46]
Lower 9.4506]
Measuring directions
Unit mm [in.]
Measured Value
Part's Name Cylinder Liner Bore Diameter Part's Name Cylinder Liner Bore Diameter
No. Direction A B C No. Direction A B C
X X
1 9
Y Y
X X
2 10
Y Y
X X
3 11
Y Y
X X
4 12
Y Y
X X
5 13
Y Y
X X
6 14
Y Y
X X
7 15
Y Y
X X
8 16
Y Y
Person In
REMARK Approved By Checked By
Charge
No. 2(1/2)
INSPECTION RECORD SHEET
SU
Engine Model
Company Serial No. DATE
Inspection Measurement of Anti-polish-Ring spec. Cylinder Liner
Point Inner Diameter UNIT mm

Nominal
Value
Standard Limit
255.000
A Liner inside dimeter φ255 ～255.056 255.400
for Anti-polish-Ring [10.03] [10.0393 [10.05]
Transverse to piston pin ～10.0415]
Parallel to piston ring
Y
A Detail
D
[0.87]
X
Measuring directions 20
Unit mm
[in.]
Measured Value
Liner inside dimeter for Liner inside dimeter for
Part's Name Part's Name
Anti-polish-Ring Anti-polish-Ring
No. Direction D No. Direction D
X X
1 9
Y Y
X X
2 10
Y Y
X X
3 11
Y Y
X X
4 12
Y Y
X X
5 13
Y Y
X X
6 14
Y Y
X X
7 15
Y Y
X X
8 16
Y Y
Person
In Charge
No. 2(2/2)
SU
Engine Model
Company Serial No. DATE
Inspection
Measurement of Anti-polish-Ring Inside and Outside Diameter UNIT mm
Point

Mean value
Nominal of four Limit
Value directions
Anti-polish-Ring φ238 288.400
Inside Diameter
－
[9.37] [11.35]
A Anti-polish-Ring φ255
－
255.400
B Outside Diameter [10.03] [10.55]
C
D
（４ヶ所）
(4 directions)
Measured Value
Part's Name Anti-polish-Ring Inside Diameter Part's Name Anti-polish-RingOutside Diameter
No. A B C D Mean No. A B C D Mean
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
Person
In Charge
No. 3(1/6) INSPECTION RECORD SHEET
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Valve Guide Inside Diameter and Valve Stem
Point Diameter－1/2(1/6)
UNIT mm[in.]

Y
Y Nominal
X X Standard Limit
Value
Valve Guide Inside Diameter 17.000 to 17.018
A φ17[0.67] 17.14[0.657]
(same for Inlet and Exhaust) [0.6693 to 0.6700]
A
16.91 to 16.93
B B Inlet φ17[0.67] 16.82[0.662]
Valve Stem [0.6657 to 0.6665]
C Diameter 16.88 to 16.90
C Exhaust φ17[0.67] 16.74[0.659]
[0.6646 to 0.6654]
Measured Value
Part's Name Valve Guide Inside Diameter Valve Stem Diameter
A B C A B C
No. Direction
ＸＹＸＹＸＹＸＹＸＹＸＹ
①
Inlet
②
1
①
Exhaust
②
①
Inlet
②
2
①
Exhaust
②
①
Inlet
②
3
①
Exhaust
②
①
Inlet
②
4
①
Exhaust
②
①
Inlet
②
5
①
Exhaust
②
①
Inlet
②
6
①
Exhaust
②
Person In
Charge
INSPECTION RECORD SHEET No .3(2/6)
SU
Engine Model
Company DATE
Serial No.
UNIT mm[in.]

Y
Y Nominal
X X Standard Limit
Value
A φ17[0.67] 17.14[0.657]
A
16.91 to 16.93
B B Inlet φ17[0.67] 16.82[0.662]
Valve Stem [0.6657 to 0.6665]
C Exhaust φ17[0.67] 16.74[0.659]
[0.6646 to 0.6654]
Measured Value
Part's Name Clearance
Ａ B C
No. Direction
Max. Min. Max. Min. Max. Min.
①
Inlet
②
1
Ex- ①
haust ②
①
Inlet
②
2
Ex- ①
haust ②
①
Inlet
②
3
Ex- ①
haust ②
①
Inlet
②
4
Ex- ①
haust ②
①
Inlet
②
5
Ex- ①
haust ②
①
Inlet
②
6
Ex- ①
haust ②
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
UNIT mm[in.]

Y
Y Nominal
X X Standard Limit
Value
A φ17[0.67] 17.14[0.657]
A
16.91 to 16.93
B B Inlet φ17[0.67] 16.82[0.662]
Valve Stem [0.6657 to 0.6665]
C Exhaust φ17[0.67] 16.74[0.659]
[0.6646 to 0.6654]
Measured Value
A B C A B C
No. Direction
①
Inlet
②
7
①
Exhaust
②
①
Inlet
②
8
①
Exhaust
②
①
Inlet
②
9
①
Exhaust
②
①
Inlet
②
10
①
Exhaust
②
①
Inlet
②
11
①
Exhaust
②
①
Inlet
②
12
①
Exhaust
②
Person In
Charge
INSPECTION RECORD SHEET No. 3(4/6)
SU
Engine Model
Company DATE
Serial No.
UNIT mm[in.]

Y
Y Nominal
X X Standard Limit
Value
A φ17[0.67] 17.14[0.657]
A
16.91 to 16.93
B B Inlet φ17[0.67] 16.82[0.662]
Valve Stem [0.6657 to 0.6665]
C Exhaust φ17[0.67] 16.74[0.659]
[0.6646 to 0.6654]
Measured Value
Ａ B C
No. Direction
①
Inlet
②
7
Ex- ①
haust ②
①
Inlet
②
8
Ex- ①
haust ②
①
Inlet
②
9
Ex- ①
haust ②
①
Inlet
②
10
Ex- ①
haust ②
①
Inlet
②
11
Ex- ①
haust ②
①
Inlet
②
12
Ex- ①
haust ②
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
UNIT mm[in.]

Y
Y Nominal
X X Standard Limit
Value
A φ17[0.67] 17.14[0.657]
A
16.91 to 16.93
B B Inlet φ17[0.67] 16.82[0.662]
Valve Stem [0.6657 to 0.6665]
C Exhaust φ17[0.67] 16.74[0.659]
[0.6646 to 0.6654]
Measured Value
A B C A B C
No. Direction
①
Inlet
②
13
①
Exhaust
②
①
Inlet
②
14
①
Exhaust
②
①
Inlet
②
15
①
Exhaust
②
①
Inlet
②
16
①
Exhaust
②
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
UNIT mm[in.]

Y
Y Nominal
X X Standard Limit
Value
A φ17[0.67] 17.14[0.657]
A
16.91 to 16.93
B B Inlet φ17[0.67] 16.82[0.662]
Valve Stem [0.6657 to 0.6665]
C Exhaust φ17[0.67] 16.74[0.659]
[0.6646 to 0.6654]
Measured Value
Ａ B C
No. Direction
①
Inlet
②
13
Ex- ①
haust ②
①
Inlet
②
14
Ex- ①
haust ②
①
Inlet
②
15
Ex- ①
haust ②
①
Inlet
②
16
Ex- ①
haust ②
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Piston Bushing Inside Diameter and Piston
Point Pin Diameter (1/2)
UNIT mm[in.]
Measuring Locations
Y
X Y X
Ԙ
ԙ
Standard
Nominal Value Standard Limit
100.05 to 100.11
Piston Bushing Inside Diameter φ100[3.937] 100.18[3.9441]
[3.9390 to 3.9413]
99.985 to 100.000
Piston Pin Diameter φ100[3.937] 0.09[0.0035]
[3.9364 to 3.9370]
Measured Value
Part's Name Piston Bushing Inside Diameter Piston Pin Diameter Clearance
No. Direction ＸＹＸＹ Max. Min.
①
1
②
①
2
②
①
3
②
①
4
②
①
5
②
①
6
②
①
7
②
①
8
②
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Piston Bushing Inside Diameter and Piston
Point Pin Diameter (2/2)
UNIT mm[in.]
Measuring Locations
Y
X Y X
Ԙ
ԙ
Standard
100.05 to 100.11
Piston Bushing Inside Diameter φ100[3.937] 100.18[3.9441]
[3.9390 to 3.9413]
99.985 to 100.000
Piston Pin Diameter φ100[3.937] 0.09[0.0035]
[3.9364 to 3.9370]
Measured Value
Part's Name Piston Bushing Inside Diameter Piston Pin Diameter Clearance
①
9
②
①
10
②
①
11
②
①
12
②
①
13
②
①
14
②
①
15
②
①
16
②
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Connecting Rod Bearing Inside Diameter and
Point Crankshaft, Crankpin Diameters (1/3)
UNIT mm[in.]
Measuring Locations
Y
X
Approx.17 Approx.17
[0.6693] [0.6693] X Y1
15 Y2
15
Standard
Degree of circulality of (Max.Value-min.Value)
connecting rod bearing inside diameter ≦0.1[0.0039]
φ180 0 to -0.025 0.136 to 0.500
Crankpin Diameter
[7.0866] [0 to -0.001] [0.0054 to 0.0197]
Clearance Between 0.136 to 0.500
Connecting Rod Bearings with Crankpin [0.0054 to 0.0197]
Measured Value
Crankshaft,
Part's Name Connecting Rod Bearing Inside Diameter Clearance
Crankpin Diameters
Ｎｏ. Direction X Y X Y1 Y2 Degree of circulality Max. Min.
①
1
②
①
2
②
①
3
②
①
4
②
①
5
②
①
6
②
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
UNIT mm[in.]
Measuring Locations
Y
X
Approx.17 Approx.17
[0.6693] [0.6693] X Y1
15 Y2
15
Standard
φ180 0 to -0.025 0.136 to 0.500

Crankpin Diameter
[7.0866] [0 to -0.001] [0.0054 to 0.0197]

Measured Value
Crankshaft, Crankpin
Diameters
①
7
②
①
8
②
①
9
②
①
10
②
①
11
②
①
12
②
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
UNIT mm[in.]
Measuring Locations
Y
X
Approx.17 Approx.17
[0.6693] [0.6693] X Y1
15 Y2
15
Standard
φ180 0 to -0.025 0.136 to 0.500
Crankpin Diameter
[7.0866] [0 to -0.001] [0.0054 to 0.0197]
Measured Value
Crankshaft, Crankpin
Diameters
①
13
②
①
14
②
①
15
②
①
16
②
Person In
Charge
No. 6(1/2）
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Rocker Bushing Inside Diameter and Rocker
Point Shaft Diameter (1/2)
UNIT mm[in.]

Y Y Nominal
Standard Limit
X
Value
X
48.04
Inlet Rocker Bushing φ48 to 48.14 48.24
Exhaust Inside Diameter [1.89] [1.891 to [1.899]
1.895]
47.984
Rocker Shaft φ48 to 48.000 47.95
Diameter [1.89] [1.8891 to [1.888]
1.8898]
Measured Value
Rocker Bushing Inside
Part's Name Rocker Shaft Diameter Clearance
Diameter
Inlet
1
Exhaust
Inlet
2
Exhaust
Inlet
3
Exhaust
Inlet
4
Exhaust
Inlet
5
Exhaust
Inlet
6
Exhaust
Inlet
7
Exhaust
Inlet
8
Exhaust
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Rocker Bushing Inside Diameter and Rocker
Point Shaft Diameter (2/2)
UNIT mm[in.]

Y Y Nominal
Standard Limit
X
Value
X
48.04
Inlet Rocker Bushing φ48 to 48.14 48.24
Exhaust Inside Diameter [1.89] [1.891 to [1.899]
1.895]
47.984
Rocker Shaft φ48 to 48.000 47.95
Diameter [1.89] [1.8891 to [1.888]
1.8898]
Measured Value
Rocker Bushing Inside
Part's Name Rocker Shaft Diameter Clearance
Diameter
Inlet
9
Exhaust
Inlet
10
Exhaust
Inlet
11
Exhaust
Inlet
12
Exhaust
Inlet
13
Exhaust
Inlet
14
Exhaust
Inlet
15
Exhaust
Inlet
16
Exhaust
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Piston Pin Bore Diameter and Piston Pin
Point Diameter (1/2)
UNIT mm[in.]

Y Nominal
Standard Limit
Value
X 100.002 to
Y Piston Pin Bore φ100 100.012 0.09
Diameter [3.937] [3.9371 to [0.0035]
X A B A 3.9375]
99.985 to
B
Piston Pin φ100 100.000 0.09
Diameter [3.937] [3.9364 to [0.0035]
3.937]
The limit shows clearance to the piston pin.
Measured Value
Part's Name Piston Pin Bore Diameter Piston Pin Diameter Clearance
Ａ
1
B
Ａ
2
B
Ａ
3
B
Ａ
4
B
Ａ
5
B
Ａ
6
B
Ａ
7
B
Ａ
8
B
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Piston Pin Bore Diameter and Piston Pin
Point Diameter (2/2)
UNIT mm[in.]

Y Nominal
Standard Limit
Value
X 100.002 to
Y Piston Pin Bore φ100 100.012 0.09
Diameter [3.937] [3.9371 to [0.0035]
X A B A 3.9375]
99.985 to
B
Piston Pin φ100 100.000 0.09
Diameter [3.937] [3.9364 to [0.0035]
3.937]
The limit shows clearance to the piston pin.
Measured Value
Part's Name Piston Pin Bore Diameter Piston Pin Diameter Clearance
Ａ
9
B
Ａ
10
B
Ａ
11
B
Ａ
12
B
Ａ
13
B
Ａ
14
B
Ａ
15
B
Ａ
16
B
Person In
Charge
INSPECTION RECORD SHEET No. 8
SU
Engine Model
Company DATE
Serial No.
Inspection
Point
Measurement of Valve Clearance UNIT mm[in.]
Measuring Locations
Standard
A Standard
Inlet 0.6[0.02362]
Valve Clearance(A)
Exhaust 0.8[0.03150]
Measured Value
Valve Clearance Valve Clearance
No. Inlet Exhaust No. Inlet Exhaust
Before Adjustment Before Adjustment
1 9
After Adjustment After Adjustment
2 10
3 11
4 12
5 13
6 14
7 15
8 16
Person In
Charge
No. 9 INSPECTION RECORD SHEET
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Injection Start Pressure of Fuel Injection 2
UNIT MPa(kgf/cm )
Point Nozzle [psi]
Measuring Locations
Standard
Nominal Value Standard
34.3 34.8 to 35.3
Injection Start
(350) (355 to 360)
Pressure
[4979] [5050 to 5121]
Measured Value
Injection Injection Injection Injection
Pressure Service Pressure Pressure Service Pressure
Ｎｏ. Ｎｏ.
Before Hours (h) After Before Hours (h) After
Adjustment Adjustment Adjustment Adjustment
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Camshaft Bushing Inside Diameter and
Point Camshaft Journal Diameter (1/2)
UNIT mm[in.]
Measuring Locations
X
;
Standard
φ128 128.007 to 128.073
Camshaft Bushing Inside Diameter
[5.0394] [5.0396 to 5.0422]
φ128 127.890 to 127.915

Camshaft Journal Diameter
[5.0394] [5.0350 to 5.0360]
0.400
Above Clearance
[0.0157]
Measured Value
Part's Name Camshaft Bushing Inside Diameter Camshaft Journal Diameter Clearance
No. ＸＹＸＹ Max. Min.
R1
R2
R3
R4
R5
R6
R7
R8
Person In
Charge
SU
Engine Model
Company DATE
Serial No.
Inspection Measurement of Camshaft Bushing Inside Diameter and
Point Camshaft Journal Diameter (2/2)
UNIT mm[in.]
Measuring Locations
X
;
Standard
φ128 128.007 to 128.073
Camshaft Bushing Inside Diameter
[5.0394] [5.0396 to 5.0422]
φ128 127.890 to 127.915

Camshaft Journal Diameter
[5.0394] [5.0350 to 5.0360]
0.400
Above Clearance
[0.0157]
Measured Value
Part's Name Camshaft Bushing Inside Diameter Camshaft Journal Diameter Clearance
No. ＸＹＸＹ Max. Min.
L1
L2
L3
L4
L5
L6
L7
L8
Person In
Charge
INSPECTION RECORD SHEET No. 11
SU
Engine Model
Company DATE
Serial No.
Inspection
Point
Measurement of Crankshaft End Play UNIT mm[in.]
Measuring Locations
Bar
Standard
Standard Limit
Crankshaft End 0.38 to 0.51 0.60

Play [0.015 to 0.02] [0.024]
Measured Value
During Disassembly After Reassembly
Person In
Charge
No. 12 INSPECTION RECORD SHEET
SU
Engine Model
Company DATE
Serial No.
Inspection
Point
Measurement of Crankshaft Deflection UNIT mm[in.]
Measuring Locations
Standard
Standard
11mm[0.43in.]Serraion
0.029[0.00114] or less
Connecting Rod
Crankshaft Deflection
7・9mm[0.27･0.35in.]Serraion
0.026[0.00120] or less
Connecting Rod
Measured Value
Clearance
① ② ③ ④ ⑤
Max. Min.
Measurement 0
of Deflection (Standard)
Person In
Charge
SUPPLEMENT 3 TURBOCHARGER TF15
Chapter 1 Precautions for Disassembly and Assembly

1. Precautions for Disassembly and Assembly

1. SERVICE DATA

1. SERVICE TOOLS
Chapter 4 Dedicated Workbench for Turbocharger (Preparation by Yourself)

1. Dedicated Workbench for Turbocharger (Preparation by Yourself)
Chapter 5 Turbocharger - Disassemble and Inspect

1. Turbocharger - Disassemble and Inspect
Chapter 6 Cleaning
1. Cleaning
Chapter 7 Turbocharger - Inspect

1. Turbocharger - Inspect
Chapter 8 Turbocharger - Assemble

1. Turbocharger - Assemble
Chapter 9 Failure Causes and Countermeasures

1. Failure Causes and Countermeasures
Foreword
Foreword
This service manual describes the maintenance and cleaning/inspection procedures, and
specifications for Mitsubishi turbochargers.
Read through this manual carefully and understand the work procedures fully before dis-
assembling, inspecting, repairing or assembling the turbocharger.
I
Foreword
HOW TO USE THIS MANUAL
This service manual contains the maintenance procedures such as structures, maintenance standards, disassembling, inspection
and assembling of Mitsubishi turbochargers.
Brief summary of the system used in compiling this service manual:
(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indica-
tion of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) In this manual, important safety or other cautionary instructions are emphasized with the following head marks.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
Emphasizes important matter, or indicates information useful for operation or maintenance
NOTIE: of the engine.
Terms used in this manual

Standard value
means the quantitative requirement for dimension of a part, clearance between parts or standard performance of engine. The
values are rounded off for the inspection job, and do not necessarily conform to the design values.
Unit of Measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in { } and
U.S. customary values are in [ ]. For the conversion, the following rates are used.
Pressure: 1 MPa = 10.197 kgf/cm2
Torque: 1 N·m = 0.10197 kgf•m
II
1. Precautions for Disassembly and Assembly ........................................................ 1-3
1.1 Disassembling .......................................................................................................................... 1-3
1.2 Assembling ............................................................................................................................... 1-3
1-1
1. Precautions for Disassembly and Assembly

This service manual contains the recommended practices to
service the engine. The manual also contains dedicated spe-
cial tools made for the work, and the basic safety cautions to
obey when working.
Note that this manual does not cover all potential hazards
that could occur during maintenance, inspection and service
works of the engine.
When working on the engine, follow the related instructions
in this manual and also pay attention to the following:
1.1 Disassembling
(1) Use correct tools and instruments. Otherwise, serious
damage or accident may result.
(2) Use a footing or workbench to place disassembled parts
as required, and obey the disassembly procedure in this
manual.
(3) Place the engine parts in good order to prevent from
missing.
(4) Pay attention to assembling marks. Put your marks on
the parts, if necessary, to ensure correct assembling.
(5) Carefully check each part for defects during disassem-
bling or cleaning. Do not miss symptoms which cannot
be found after finishing the disassembling or cleaning.
1.2 Assembling
(1) Thoroughly clean the compressor cover and turbine
housing using cleaner and completely dry with com-
pressed air.
(2) Use correct tools and instruments.
(3) Use only high-quality greases of appropriate types. Be
sure to apply adhesive on the part wherever specified.
(4) Use a torque wrench to tighten parts correctly when
their tightening torques are specified. Refer to Tighten-
ing torque table.
(5) Replace the O-rings with new ones.
1-3
1. SERVICE DATA ........................................................................................................ 2-3
1.1 Maintenance Service Data........................................................................................................ 2-3
1.2 Tightening torque table ............................................................................................................. 2-3
2-1
1. SERVICE DATA
1.1 Maintenance Service Data
Unit: mm [in.]
Part or item Standard value Limit value Remark
36.014
Inside diameter of bearing-fitted housing section -
[1.4179]
35.847
Outside diameter -
[1.4113]
24.034
Bearing Inside diameter -
[0.9462]
23.440
Length -
[0.9228]
23.996
Journal outside diameter -
[0.9447]
Shaft & turbine wheel assembly
0.015
Shaft runout -
[0.0006]
0.050 to 0.200
Piston ring end gap - When installing the insert piston ring
[0.0020 to 0.0079]
Clearance between shaft & turbine wheel assembly and turbine 0.58 to 1.32 [0.0228
-
housing to 0.0520]
0.075 to 0.135
Looseness of axis for shaft & turbine wheel assembly -
[0.0030 to 0.0053]
Clearance between turbine back plate and turbine wheel back face 0.855 to 1.355 Stand the cartridge assembly vertically
-
[0.0337 to 0.0533] placing the turbin wheel upward
1.2 Tightening torque table
Thread Tightening torque (Torque method)

Part to be installed Remark
Dia. × Pitch N·m kgf·m lbf·ft
Note (Angle method)
Compressor wheel (nut) 1/2-20 UNF Apply Loctite on threads
88 ± 2.0 9.0 ± 0.2 64.91 ± 1.47
Compressor cover (V-clamp) 1/4-28 UNF 8.8 ± 1.0 0.9 ± 0.1 6.491 ± 0.73
Flange (Bolt) 10 × 1.5 24 ± 2.0 2.4 ± 0.2 2.4 ± 17.7
Nozzle ring (Bolt) 6 × 1.0 5.0 ± 2.0 0.5 ± 0.2 0.5 ± 3.69 Apply Molykote on threads.
Turbine housing
10 × 1.5 24 ± 2.0 2.4 ± 0.2 2.4 ± 17.7
(Bolt)
Note: (Controlled angle method) Tighten nut to 69 N·m {7.04 kgf·m} [50.89 lbf·ft], loosen and tighten back to 9.8 N·m{1.0
kgf·m} [7.23 lbf·ft], then turn to an angle of 90 ± 3°.
Control the axial elongation to 0.06 to 0.11 mm. Consider the torque value as a reference. Tighten the nut to 0.06 mm elon-
gation exceeding the 167 N·m {17.03 kgf·m} [123.17 lbf·ft] torque value if the elongation is below 0.06 mm [0.0024 in.].
Replace the compressor wheel and lock nut I the elongation exceeds 0.11 mm [0.0043 in.].
2-3
1. SERVICE TOOLS...................................................................................................... 3-3
1.1 Special Tools ............................................................................................................................ 3-3
3-1
1. SERVICE TOOLS
1.1 Special Tools
Pliers 49160-90101 Snap ring installation/removal
Pliers 49160-90201 Snap ring installation/removal
3-3
1. Dedicated Workbench for Turbocharger (Preparation by Yourself)................... 4-3
4-1
1. Dedicated Workbench for Turbocharger (Preparation by Yourself)

Make the dedicated work bench referring to the dimension in the table below.
Unit: mm [in.]
A B C
0 [0.00]
140 [5.51] 84.3 [3.319] 32 [1.26]-0.4 [-0.016]
Bolt fixation,
rimless type
Cuopling fixation A
rim type
Workbench
B
Socket
Dedicated Workbench for Turbocharger (Preparation by Yourself)
4-3
1. Turbocharger - Disassemble and Inspect ............................................................. 5-3
1.1 Turbocharger - Disassemble and Inspect................................................................................. 5-3
1.2 Turbine Housing - Remove....................................................................................................... 5-4
1.3 Flange and Nozzle Ring - Remove........................................................................................... 5-4
1.4 Setting on the Dedicated Workbench ....................................................................................... 5-4
1.5 Compressor Cover - Remove ................................................................................................... 5-5
1.6 Diffuser - Remove..................................................................................................................... 5-5
1.7 Compressor Wheel - Remove .................................................................................................. 5-5
1.8 Snap Ring - Remove ................................................................................................................ 5-5
1.9 Insert and Oil Deflector - Remove ............................................................................................ 5-6
1.10 Shaft & Turbine Wheel Assembly - Remove ............................................................................ 5-6
1.11 Snap Ring and Bearing - Remove ............................................................................................ 5-6
5-1
1. Turbocharger - Disassemble and Inspect

1.1 Turbocharger - Disassemble and Inspect
29
30
Worn face of thrust bearing side 31
28
27
Bended wing, damage, 23
22
contact of rear face, 21
gas corrosion 20
19 Damage
16
18 1
17
Contact with 15
compressor wheel 14
9 13 Replace 4
5
7
10 8
Damage
3
24
25
2 26 Contact with turbine wheel,
32 crack, deformation
12
Bended wing, damaged ring gap,
11 contact of rear face, damage, corrosion
Contact with turbine wheel,

damage
Damaged bearing hole, gas corrosion,

Replace
deformed flange of turbine side
Turbocharger - Disassemble and Inspect (TD15)

1 Lagging 12 O-ring 22 Thrust bearing
2 Bolt 13 Lock nut 23 Thrust ring (turbine side)
3 Turbine housing 14 Compressor wheel 24 Shaft & turbine wheel assembly
4 Bolt 15 Snap ring 25 Piston ring
5 Flange 16 Insert 26 Turbine back plate
6 Wiring 17 Flinger sleeve 27 Bearing (compressor side)
7 Lock plate & bolt 18 Piston ring 28 Snap ring
8 Nozzle ring 19 O-ring 29 Snap ring
9 V-clamp 20 Oil deflector 30 Bearing (turbine side)
10 Compressor cover 21 Thrust ring (compressor side) 31 Snap ring
11 Diffuser 32 Bearing housing
Carefully handle the compressor wheel and turbine wheel during disassembly and assembly, because blades can
be easily bent when dropped or hit.
5-3
1.2 Turbine Housing - Remove
Compressor cover
(a) Since it is important to ensure proper positioning Bolt

of bearing housing and turbine housing in assem-
bly, be sure to place matching marks with a punch
Bearing housing
or marker.
(b) When removing the turbine housing, do not hit or
pry out, as the blades are easily bent.
(1) Using the box wrench, remove the parts below accord-
Turbine housing
ing to the type.
(2) Lightly tap the entire periphery of turbine housing with Turbine Housing - Remove
a soft hammer, and remove the turbine housing.
1.3 Flange and Nozzle Ring - Remove
Bolt
When it is hard to remove the flange because of car-
bon, apply lubricant oil to make it easy. Do not
remove forcibly, otherwise it damage. Jack bolt
(M20×1.5) Flange
Flange - Remove
Wire ring
(1) Remove bolt and then attach jack bolt to the two jack
bolt holes of flange.
(2) Screw the jack bolt in the hole evenly and then remove Turbine
housing
flange and wiring from turbine housing.
Flange - Remove
Nozzle Ring - Remove
Remove bolt and lock plate. Then remove nozzle ring from Bolt
turbine housing.
Nozzle ring
Lock plate
Turbine
housing
Nozzle Ring - Remove

1.4 Setting on the Dedicated Workbench
Prepare the dedicated workbench and place the bearing
housing with the turbine wheel side facing downward. At
this time, securely install the turbine wheel shaft end in the
socket of dedicated workbench. (When dedicated work-
bench is used )
Note: Refer to "Dedicated Workbench for Turbocharger" to
make the workbench. Workbench
Setting on the Dedicated Workbench
5-4
1.5 Compressor Cover - Remove
Compressor cover
(a) Since it is important to ensure proper positioning
of compressor cover and bearing housing in
assembly, be sure to place matching marks with a
punch or marker.
(b) When removing the compressor cover, be careful 㨂 clamp
not to hit or pry out, as the blades are easily bent.
(1) Use the box wrench to reduce the tension of the V-
clamp.
(2) Lightly tap the entire periphery of compressor cover Compressor Cover - Remove
with a soft hammer, and remove the compressor cover.
1.6 Diffuser - Remove

(1) Lightly tap the entire periphery of diffuser with a plas-
tic hammer, and remove it.
Diffuser
(2) Remove O-ring from bearing housing.
㧻-ring
㧻-ring
Bearing
housing
Diffuser - Remove
1.7 Compressor Wheel - Remove
Compressor Lock nut

(a) Carefully handle the compressor wheel, as the
wheel
blades are easily bent.
(b) The lock nut has a left-hand thread. Pay attention
to the rotational direction when disassembling.
(1) Remove lock nut that holds the compressor wheel.
(2) Remove the compressor wheel while turning lightly by
hand.
Compressor Wheel - Remove

1.8 Snap Ring - Remove
Cover the snap ring with your hand to prevent it from Pliers
P/N: 49160-90101
flying out in case pliers lose grip.
Snap ring
Remove the snap ring with the pliers.
Snap Ring - Remove

5-5
1.9 Insert and Oil Deflector - Remove

(1) Using two screwdrivers, gently pry out the insert from
Flinger sleeve Insert
the bearing housing. Piston ring
(2) Remove the flinger sleeve together with the piston ring O-ring
Bearing
from the insert. housing Oil deflector
Thrust ring
(3) Remove the following parts from the bearing housing. (Compressor side)
O-ring Thrust bearing
Oil deflector Thrust ring
(Turbine side)
Thrust ring (compressor side)
Thrust bearing
Thrust ring (turbine side)
Insert and Oil Deflector - Remove
1.10 Shaft & Turbine Wheel Assembly - Remove
Shaft &
When assembling, use the new lock washer. Do not Turbine wheel
assembly
reuse.
(1) While gripping the shaft of the shaft & turbine wheel
Bearing
assembly with one hand, hold the bearing housing with housing
the other hand and remove the shaft & turbine wheel
assembly from the turbine housing.
Shaft & Turbine Wheel Assembly – Remove (1)

(2) Turn bearing housing upside down to remove the fol- Bearing
lowing parts (turbine wheel side up). housing
Shaft & turbine wheel assembly
Piston ring Shaft &
turbine wheel
Turbine back plate
Bearing (compressor side) Piston ring
Turbine
Bearing back plate
(Compressor side)
Shaft & Turbine Wheel Assembly – Remove (2)
1.11 Snap Ring and Bearing - Remove
Snap ring
(Compressor side)
(a) Remove the snap ring with the pliers.
(b) Carefully remove the snap ring, making sure not to Bearing housing
damage the inner surface of the bearing housing
and the sealing surface (turbine side) of the piston
ring. Snap ring (Turbine side)
Remove the following parts from bearing housing.
Bearing (Turbine side)
Snap ring (compressor side) Pliers
Snap ring (Turbine side)
P/N: 49160-90201
Snap ring (turbine side)
Snap Ring and Bearing - Remove
Bearing (turbine side)
Snap ring (turbine side)
5-6
Chapter 6 Cleaning
1. Cleaning.................................................................................................................... 6-3
6-1
Chapter 6 Cleaning
Chapter 6 Cleaning
1. Cleaning
Compressor wheel
(a) When using a commercially available neutral
detergent, use non corrosive detergent.
(b) Exercise care not to damage any part.
*
(c) Where shot-blasting is necessary, cover the both
end surfaces of the compressor wheel, and
screws, shafts, and groove for ring of the turbine
Shaft &
shaft & turbine wheel assembly to protect their Turbine wheel
surfaces from being rugged or sore before the assembly
cleaning operation. Cleaning Procedure of Turbocharger

The workshops specialized in maintenance of turbocharger
often use a blasting equipment for cleaning the parts. An
effective alternative to this, follow the instructions below:
Note: Do not apply shot blasting on the parts marked with *
in the figure on the right. Do not spray both end surfac- When using ultrasonic cleaning system together,
extraneous matter can be removed well.
es of the compressor wheel, and shaft section of the
shaft & turbine wheel assembly.
(1) Visually inspect the part conditions before cleaning for
any burns and abrasions which may not be observable
after cleaning.
(2) Soak the disassembled parts in the inflammable solvent
(e.g. Die Cleaner T-30 manufactured by Daido Chemi-
cal Industry Corp.) to remove oil contaminants and car-
Turbocharger - Clean
bon deposits. However, do not soak the O-rings,
bearings, and thrust bearings.
(3) Blow compressed air to the entire inner and outer sur-
faces.
Blowing Compressed Air

(4) Scrape off the deposits using a plastic scraper or a bris-
tle brush.
Note: Do not use a metallic brush.
Scraping Off Deposits
6-3
Chapter 6 Cleaning
(5) Blow compressed air to the entire inner and outer sur-
faces again.
Apply clean engine oil on each sliding face. If rust is
found at the threads, shaft, or ring groove, remove with
buffing. Do not use a file, which will make the surface
rough.
Blowing Compressed Air
Engine Oil - Apply
6-4
1. Turbocharger - Inspect............................................................................................ 7-3
1.1 Bearing housing........................................................................................................................ 7-3
1.2 Bearing ..................................................................................................................................... 7-3
1.3 Shaft & Turbine Wheel Assembly ............................................................................................. 7-4
1.4 Insert, compressor plate and labyrinth plate............................................................................. 7-4
7-1
1. Turbocharger - Inspect
1.1 Bearing housing
Inside diameter of bearing-fitted section - Measure
If the measured diameter exceeds the service limit, replace
the bearing housing.

Inside diameter of bearing-fitted housing 36.014 mm
section [1.4179 in.]
Inside Diameter of Bearing-Fitted Section - Measure

1.2 Bearing
1.2.1 Bearing outside diameter - Measure
If the measured diameter is less than the service limit,
replace the bearing.

35.847 mm
[1.4113 in.]
Bearing Outside Diameter - Measure

1.2.2 Bearing inside diameter - Measure
If the measured diameter exceeds the service limit, replace
the bearing.

24.034 mm
[0.9462 in.]
Bearing Inside Diameter - Measure

1.2.3 Bearing length - Measure
If the measured length is less than the service limit, replace
the bearing.

23.440 mm
Bearing length
[0.9228 in.]
Bearing Length - Measure
7-3
1.3 Shaft & Turbine Wheel Assembly

1.3.1 Journal diameter of the shaft & turbine wheel
assembly - Measure
If the measured diameter is less than the service limit,
replace the shaft & turbine wheel assembly.
Replace the piston ring with a new one.

Journal diameter of the shaft & turbine 23.996 mm
wheel - Measure [0.9447 in.]
Journal Diameter of the Shaft & Turbine Wheel

Assembly - Measure
Replace if shaft runout is found. Do not attempt to cor-

rect the deflection.
1.3.2 Shaft runout - Measure

Set a dial gauge at a location next to the threaded end of the
shaft, and measure the shaft runout.
If the runout indicated by the dial gauge exceeds the service
limit, replace the shaft & turbine wheel assembly.
If the surface of shaft and journal is rough, set the shaft &
turbine wheel on a lathe supporting both ends, and gently
polish the surface using #400 sandpaper and engine oil
while turning at 300 to 600 min-1.
Measurement item Limit value Shaft Runout - Measure

0.015 mm
Shaft runout
[0.0006 in.]
1.4 Insert, compressor plate and labyrinth plate

Piston ring end gap - Measure
Install a new piston ring squarely in the insert, compressor
plate and labyrinth plate, then measure the piston ring end Insert
Gap
gap. Piston ring
If the end gap deviates from the assembly standard, replace
the insert, compressor plate or labyrinth plate with a new
one.

0.050 to 0.200 mm
Piston ring end gap
[0.0020 to 0.0079 in.]
Piston Ring End Gap - Measure
7-4
1. Turbocharger - Assemble ....................................................................................... 8-3
1.1 Turbocharger - Assemble ......................................................................................................... 8-3
1.2 Shaft & Turbine Wheel Assembly and Bearing - Install ............................................................ 8-4
1.3 Thrust bearing - Install .............................................................................................................. 8-5
1.4 Oil deflector - Install .................................................................................................................. 8-5
1.5 O-ring - Install ........................................................................................................................... 8-5
1.6 Insert and Sub-assembly - Install ............................................................................................. 8-6
1.7 Snap Ring - Install .................................................................................................................... 8-6
1.8 Clearance Between Turbine Wheel and Turbine Housing (Axial Direction) - Measure ............ 8-7
1.9 Compressor wheel - Install ....................................................................................................... 8-7
1.10 Play of shaft & turbine wheel assembly in axial direction - Measure ........................................ 8-7
1.11 Diffuser - Install......................................................................................................................... 8-8
1.12 Compressor Cover - Install ....................................................................................................... 8-8
1.13 Clearance between turbine back plate and turbine wheel assembly - Measure....................... 8-8
1.14 Flange and nozzle ring - Install................................................................................................. 8-9
1.15 Turbine housing - Install ........................................................................................................... 8-9
8-1
1. Turbocharger - Assemble
1.1 Turbocharger - Assemble
8.8±1.0 N·m 5.0±2.0 N·m 24±2.0 N·m

{0.9±0.1 kgf·m} {0.5±0.2 kgf·m} {2.4±0.2 kgf·m}
[6.51±0.72 lbf·ft] [3.69±1.48 lbf·ft] [17.70±1.77 lbf·ft]
Detail drawing A
24±2.0 N·m
Lock nut (Left-hand thread) {2.4±0.2 kgf·m}
Thighten the lock nut to the tightening tourque of [17.70±1.77 lbf·ft]
69 N·m {7.04 kgf·m} [50.89 lbf·ft], loose it.
Apply LOCTITE to lock nut thread or shaft thread.
Retighten the lock nut to the tightening tourque of
9.8 N·m {1 kgf·m} [7.23 lbf·ft].
Then, tighten to another 90±3°.
Turbocharger - Assemble
(a) After installing the overhauled turbocharger on the engine, crank the engine with the starter to circulate lubricat-
ing oil through the turbocharger.
(b) If blades are damaged or cracked, do not use the part.
(c) Only if one blade is slightly deflected or scratched, reuse may be acceptable. In this case, do not attempt to cor-
rect the blade deflection.
Replace piston rings and O-rings with new ones when assembling.
8-3
1.2 Shaft & Turbine Wheel Assembly and Bearing - Install
(a) Install the snap ring with pliers. After installing the
snap ring, rotate the ring with a finger to make
Apply MOLYKOTE or
sure it rotates smoothly. engine oil
(b) Apply engine oil or MOLYKOTE on the outside
and inside surfaces of the bearing before installa-
tion.
(c) Do not expand the piston ring excessively or twist
the ends when installing on the shaft & turbine
wheel assembly. Apply MOLYKOTE or Engine Oil.
(d) After installing the piston ring in the ring groove,
Snap ring
apply MOLYKOTE or engine oil on the ring before (Compressor side)
assembly.
(e) Do not apply excessive force before centering the Bearing housing
shaft properly during the installation of the shaft &
turbine wheel assembly.
(f) Use new lock washer and bend it securely. Snap ring (Turbine side)
(1) Install the snap rings to the bearing housing, one on the Bearing (Turbine side)
compressor side and one on the turbine side. Pliers
Snap ring (Turbine side)
P/N: 49160-90201
(a)Assemble the following parts:
Snap Ring and Bearing - Install
Bearing housing
Snap rings (compressor and turbine sides)
Bearing (turbine side)
(b)Refer to the "Direction of snap ring" to install the snap

Snap ring
ring.
(c)Install the bearing and snap ring to the bearing hous-
ing, one bearing on the compressor side and one snap
ring on the turbine side. Refer to the "Direction of snap
ring" to install the snap ring.
(2) Place the turbine back plate over the turbine housing.
(3) Insert the piston ring into the groove on the shaft & tur-
bine wheel assembly. Bearing
(4) When installing the shaft & turbine wheel assembly
Direction of Snap Ring
mounted with the piston ring in the bearing housing,
position the piston ring on the shaft as shown in the
drawing, and insert the shaft & turbine wheel assembly
Turbine
while gently shaking. back plate
Place the gap of piston ring
to the oil inlet side
of bearing housing.
Shaft &
Turbine wheel
assembly
Bearing housing
Workbench
Shaft & Turbine Wheel Assembly – Install (1)
8-4
(5) After installing the shaft & turbine wheel assembly,

hold the shaft end and turn over the assembly so that the Shaft &
turbine wheel
compressor side faces up.
assembly
(6) Install the bearing and snap ring to the bearing housing,
one bearing on the compressor side and one snap ring
Bearing
on the turbine side. Housing
Refer to the "Direction of snap ring" to install the snap
ring.
Bearing
Shaft & Turbine Wheel Assembly – Install (2)

1.3 Thrust bearing - Install
Apply engine oil or MOLYKOTE on the both sides of thrust
bearing, and install the thrust ring (turbine side) and thrust
Thrust bearing
bearing.
Set the locating hole of thrust bearing to the spring pin of
bearing housing.
Thrust ring
Thrust Bearing - Install

1.4 Oil deflector - Install
Install the thrust ring (compressor side). Install the oil
deflector placing the buffle downward. Oil deflector
Thrust ring
(Compressor side)
Oil Deflector - Install

1.5 O-ring - Install
Apply grease on O-ring and install.
㧻-ring
O-ring - Install
8-5
1.6 Insert and Sub-assembly - Install
(a) Do not expand the piston ring excessively or twist Insert
the ends when installing on the flinger sleeve.

Piston ring
(b) Apply engine oil on the piston ring that has been
installed on the flinger sleeve, and carefully install Flinger sleeve
on the insert so as not to damage the piston ring.
(1) Assemble the sub-assembly of the insert in the follow-
ing order:
Flinger sleeve
Piston ring Insert and Sub-Assembly - Assemble
Insert
(2) After assembling the above parts, install in the bearing
housing.
1.7 Snap Ring - Install
(a) Pay attention to the mounting direction of the snap Pliers

P/N: 49160-90101
ring.
(b) Make sure to insert the snap ring in the bearing
housing groove.
Snap ring Bearing
Install the snap ring in the bearing housing with tapered side housing
facing up with pliers.
Snap Ring - Install (1)
Bearing housing
Snap ring
Snap Ring - Install (2)
8-6
1.8 Clearance Between Turbine Wheel and Turbine Housing (Axial Direction) - Measure
(1) After assembly, install bearing housing to the turbine
housing and temporarily tighten with bolts.
(2) Set the dial gauge to the end of shaft & turbine wheel
assembly. Read the dial gauge indication while moving
the shaft & turbine wheel assembly in the axial direc- Shaft &
tion. Turbine wheel
If the dial gauge indication deviates from the standard
value, locate the cause by disassembling.
Turbine
housing
Clearance between shaft & turbine wheel
0.58 to 1.32 mm Clearance Between Turbine Wheel and Turbine
assembly and turbine housing Housing - Measure
[0.0228 to 0.0520 in.]
(axial direction)
1.9 Compressor wheel - Install

(1) Install the bearing housing securely in the socket of
Apply Molykote or
dedicated workbench with the turbine wheel side facing Loctite 962T
down. on the lock nut
(left-hand thread).
(2) Install the compressor wheel to the axis of shaft and tur-
bine wheel.
(3) Apply Locktite 962T to the thread of the shaft & tur-
bine wheel assembly , and tighten the nut to the speci- Compressor Cylinder Lock nut
wheel
position
fied torque.
<Lock nut tightening method>
Compressor wheel - Install
Angle method
Compressor Wheel - Install
Tighten nut to 9.8 N·m{1.0 kgf·m} [7.23 lbf·ft], loosen
and tighten back to 9.8 N·m{1.0 kgf·m} [7.23 lbf·ft], then
turn to an angle of 90 ± 3°.
Torque method
Tighten to 88 ± 2.0 N·m {9.0 ± 0.2 kgf·m} [64.91 ± 1.47
lbf·ft].
1.10 Play of shaft & turbine wheel assembly in axial direction - Measure
(1) Install bearing housing to turbine housing again, and
tighten temporarily with bolts.
(2) Set the dial gauge to the end of shaft & turbine wheel
Shaft &
assembly. Turbine wheel
Measure the play by moving the compressor wheel in assembly
the axis direction. Compressor

wheel
If the measured amount of play deviates from the stan-
dard value, locate the cause by disassembling.

Looseness of axis for shaft & turbine 0.075 to 0.135 mm Play of Shaft & Turbine Wheel Assembly in Axial
wheel assembly [0.0030 to 0.0053 in.] Direction - Measure
8-7
1.11 Diffuser - Install

(1) Install the O-ring to the bearing housing or compressor
plate.
Diffuser
(2) Set the locating hole of diffuser to the spring pin of
㧻-ring
bearing housing.
㧻-ring
Bearing
housing
Diffuser - Install
1.12 Compressor Cover - Install
(1) Remove bearing housing from turbine housing and then
install the bearing housing turbine wheel side down to Compressor cover
the workbench. (When using workbench)
(2) Install the compressor cover to the bearing housing by
lining up the matching marks put during disassembly.
Note: When installing, be careful not to damage the O-ring.
V clamp
(3) Apply MOLYKOTE to the threads of the V-clamp. 8.8±1.0 N·m
{0.9±0.1 kgf·m}
install V-clamp and then tighten it with the specified [6.5±0.7 lbf·ft]
torque.
Compressor Cover - Install

1.13 Clearance between turbine back plate and turbine wheel assembly - Measure
Shaft &
Turbine wheel
Be sure to use two feeler gauges, and take the mea- assembly
surement at blade tips.
Place the turbocharger with the compressor cover down-
ward, measure as follows:
Measure the clearance between turbine back plate and shaft Turbine back
plate
& turbine wheel assembly with feeler gauges.
If the measured clearance deviates from the standard value, Compressor
cover
locate the cause by disassembling.
Clearance Between Turbine Back Plate and Turbine
Measurement item Standard value Wheel Assembly - Measure
Clearance between turbine back plate and 0.855 to 1.355 mm
turbine wheel back face [0.0337 to 0.0533 in.]
8-8
1.14 Flange and nozzle ring - Install

Nozzle Ring - Install
Bolt 5.0±2.0 N·m
(1) Install the nozzle ring to the turbine housing. Lock plate {0.5±0.2 kgf·m}
[3.61±1.45 lbf·ft]
(2) Apply MOLYKOTE to the threads of the bolt. Nozzle ring
Install the lock plate and bolt, and tighten bolts to the
Contact with
specified torque. turbine housing
Turbine
Note: Tighten the lock plate to place its plane side contacting housing
the turbine housing.
Lock plate
Nozzle Ring - Install
Flange - Install
(1) Install the wire ring and flange to the turbine housing. Bolt
(2) Apply MOLYKOTE to the threads of the bolt. 24±2.0 N·m
{2.4±0.2 kgf·m}
Tighten bolts to the specified torque. [17.36±1.08 lbf·ft]
Flange
Wire ring
Turbine
housing
Flange - Install
1.15 Turbine housing - Install
(1) Place the turbine housing downward, and install by
Compressor cover Bolt
ensuring the assembly direction with the bearing hous- 24±2.0 N·m
ing. {2.4±0.20 kgf·m}
[17.36±1.08 lbf·ft]
(2) Apply Molykote to the bolt thread, and tighten to the
specified torque. Bearing
housing
Turbine housing
Turbine Housing - Install
8-9
1. Failure Causes and Countermeasures .................................................................. 9-3
9-1
1. Failure Causes and Countermeasures
Condition Causes and Countermeasures

(1) Bearing failure and the contact between rotating parts and surrounding parts
Bearing can be damaged by the following: failure to change oil, entry of foreign object
into the feed oil pipe, operation of the engine with clogged/damaged oil filter, or fre-
quent sudden start and stop of the engine.
(2) There is no abnormality in the lubricating system, but the damage by contact between
Abnormal vibration
the rotating parts and the surrounding parts is observed. In such a case, the cause can
be the imbalance of the rotating parts or shaft deflection. Check the bearing for wear,
or check the turbine wheel or compressor wheel for damage due to entry of foreign
object.
In either case, inspect immediately and replace parts as required.
(1) Inspect the exhaust system for gas leaks.
(2) Check the exhaust pipe and muffler for deflection or carbon deposit if resistance is
increased.
Turbocharger is supposed to be normal but output is (3) Inspect air leakage from the outlet side of compressor, and clean or replace the element
decreased if air cleaner is dirty.
(4) When contaminant accumulates inside the compressor, clean the compressor by
removing the cover.
(5) Turn the rotor by hand, and if the rotor does not rotate lightly, replace.
(1) Clean or replace the element because dirty or clogged air cleaner causes oil leakage in
intake pipe.
White exhaust gas due to oil leakage in exhaust or (2) Repair or replace if waste oil pipe is clogged, flattened or deformed.
intake pipe (3) If worn piston ring or excessive worn ring groove is found, replace.
(4) If the operate of engine is continued when the bearing is defective, it leads to damage
of piston ring and causes oil to leak into the exhaust and intake pipes.
9-3
SUPPLEMENT 4 UG-Actuator
Chapter 1 GENERAL INFORMATION
Chapter 2 INSTALLATION
Chapter 3 INITIAL OPERATION
Chapter 4 PRINCIPLES OF OPERATION
Chapter 5 PRODUCT SUPPORT AND SERVICE OPTIONS
UG-ACTUATOR CONTROL SPECIFICATIONS
REVISION HISTORY
Product Manual 37512
(Revision H, 6/2004)
Original Instructions
UG-Actuator
Installation and Operation Manual

Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
General
Precautions Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
Revisions the publications page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative
to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
Proper Use modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
If the cover of this publication states "Translation of the Original Instructions"

please note:
The original source of this publication may have been updated since this
Translated translation was made. Be sure to check manual 26455, Customer Publication
Publications Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 37512
Copyright © Woodward 1992–2004
All Rights Reserved
Manual 37512 UG-Actuator
Contents
WARNINGS AND NOTICES ............................................................................III

ELECTROSTATIC DISCHARGE AWARENESS ................................................. IV
REGULATORY COMPLIANCE ........................................................................ V
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
Description ..............................................................................................................1
Available Terminal Shafts and Drive Shafts ...........................................................2
UG Governor Similarities ........................................................................................3
Hydraulic Pump ......................................................................................................3
References .............................................................................................................3
CHAPTER 2. INSTALLATION.......................................................................... 8
Introduction .............................................................................................................8
Receiving ................................................................................................................8
Storage ...................................................................................................................8
Drive Shaft Rotation ...............................................................................................8
Attitude....................................................................................................................9
Mounting Dimension ...............................................................................................9
Drive Connection ....................................................................................................9
Remote Actuator Oil Connection ..........................................................................10
Control Linkage ....................................................................................................10
Oil Supply .............................................................................................................12
Electrical Connection ............................................................................................14
Heat Exchanger Selection ....................................................................................15
CHAPTER 3. INITIAL OPERATION ................................................................ 17
CHAPTER 4. PRINCIPLES OF OPERATION ................................................... 18
Introduction ...........................................................................................................18
Increase in Load or Speed Setting .......................................................................18
Decrease in Load or Speed Setting .....................................................................19
Loss of Control Voltage ........................................................................................19
CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS ........................... 20
Product Support Options ......................................................................................20
Product Service Options .......................................................................................20
Returning Equipment for Repair ...........................................................................21
Replacement Parts ...............................................................................................21
Engineering Services............................................................................................22
Contacting Woodward’s Support Organization ....................................................22
Technical Assistance ............................................................................................23
UG-ACTUATOR CONTROL SPECIFICATIONS ............................................... 24
REVISION HISTORY .................................................................................... 25
Woodward i
UG-Actuator Manual 37512
Illustrations and Tables
Figure 1-1. The UG-Actuator ..................................................................................1

Figure 1-2. Outline Drawing of UG-Actuator ..........................................................4
Figure 1-3. Remote Mounted Actuator ...................................................................5
Figure 1-4. Drive Shaft and Terminal Shaft Configurations ...................................6
Figure 1-5. Schematic of UG-Actuator ...................................................................7
Figure 2-1. Alignment of Reference Notch and Arrow............................................9
Figure 2-2. Terminal Shaft Travel .........................................................................11
Figure 2-3. Linear Linkage....................................................................................11
Figure 2-4. Nonlinear Linkage ..............................................................................11
Figure 2-5. Oil Chart .............................................................................................13
Figure 2-6. Viscosity Comparisons .......................................................................14
Figure 2-7a. Wiring for a UG-Actuator ..................................................................15
Figure 2-7b. Wiring for a UG-Actuator with LVDT ................................................15
Figure 2-8. UG-Actuator Heat Exchanger ............................................................16
ii Woodward
Warnings and Notices

Important Definitions
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
 WARNING—Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only
(including damage to the control).
 IMPORTANT—Designates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage.
Always wear the appropriate personal protective equipment (PPE) for
Personal Protective the job at hand. Equipment that should be considered includes but is
not limited to:
Equipment
 Eye Protection
 Hearing Protection
 Hard Hat
 Gloves
 Safety Boots
 Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
Start-up property damage.
On- and off-highway Mobile Applications: Unless Woodward's

control functions as the supervisory control, customer should install
a system totally independent of the prime mover control system that
Automotive monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
Applications
control with possible personal injury, loss of life, or property
damage.
Woodward iii
To prevent damage to a control system that uses an alternator or

battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Battery Charging
Device
Electrostatic Discharge Awareness

Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
 Discharge body static before handling the control (with power to
Electrostatic the control turned off, contact a grounded surface and maintain
Precautions contact while handling the control).
 Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
 Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
iv Woodward
Regulatory Compliance
These listings are limited only to those units bearing the CSA agency
identification.
CSA: CSA Certified for Class I, Division 2, Groups A, B, C, &

D, T4 at 122 °C ambient, for use in Canada
Certificate: 160584-1365765
The UG Actuator is suitable for use in Class I, Division 2, Groups A, B, C, and D

per CSA for Canada or non-hazardous locations only.
Wiring must be in accordance with North American Class I, Division 2 wiring

methods as applicable, and in accordance with the authority having jurisdiction.
EXPLOSION HAZARD—Do not remove covers or connect/disconnect

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
Substitution of components may impair suitability for Class I,

Division 2.
RISQUE D’EXPLOSION—Ne pas enlever les couvercles, ni

raccorder / débrancher les prises électriques, sans vous en
assurez auparavant que le système a bien été mis hors
tension; ou que vous vous situez bien dans une zone non
explosive.
La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I, Division 2.
Woodward v
vi Woodward
Chapter 1.
General Information
Introduction
This manual describes the installation and operation of the UG-Actuator.
Figure 1-1. The UG-Actuator
Description
The UG-Actuator is a proportional electro-hydraulic actuator which can be used
with electronic controls which provide a 20 to 160 mA position signal. The
actuator is designed for use with Woodward 2301, 400, 43027, 500-series, and
700-series controls.
The actuator converts a given electrical signal to an output shaft position through
the action of a torque motor and follower-type pilot valve. The rotary output
actuator has 42 degrees of terminal (output) shaft travel. Recommended travel
from the no-load to the full-load position is 2/3 of full actuator travel.
The UG-Actuator is used on diesel, gas, and gasoline engines (also steam and
industrial gas turbines) to replace UG-8 type governors, providing the
advantages of electronic control and load sharing systems with the convenience
of the existing UG-8 type drive and linkage.
Woodward 1
The standard UG-Actuator provides a maximum work capacity of 19.4 J (14.3
ft-lb) in the increase direction, and 23.3 J (17.2 ft-lb) in the decrease direction. A
special actuator is available which provides 27.1 J (20.0 ft-lb) of work in both
directions. Another special actuator is the remote actuator which does not have a
drive shaft. Pressurized oil (758–2758 kPa/110–400 psi) must be supplied to the
actuator. The remote actuator has 27.1 J (20.0 ft-lb) when supplied with 2758
kPa/400 psi. Work capacity is based on the full 42 degree travel of the terminal
(output) shaft. Rated work capacity is 2/3 of maximum work capacity.
The actuator can be built with a low speed pump for speed ranges of 375 to 1100
rpm, or with a high speed pump for 600 to 1500 rpm.
The UG-Actuator is available with an LVDT for position feedback. The LVDT is
not available with the MPU option. With the LVDT, the actuator has a 10-pin
connector on the cover.
The actuator may be equipped with a special gear and magnetic pickup, using
the governor drive to sense engine speed. This permits an added convenience
when converting from a UG hydraulic-mechanical governor to an electronic
control system. Low cranking speeds may require override of the electronic
failsafe. The MPU option is not available with the 27.1 J (20.0 ft-lb) work capacity
UG-Actuator.
The MPU will sense the speed of the governor drive, which is not
necessarily the same rpm as the engine. The frequency sensed by
the MPU must match the frequency range of the electronic control.
The UG-Actuator output is directly proportional to a 20 to 160 mA signal from an

electronic control system.
This manual provides outline drawings to show the base and drive
configurations. The outline drawings include information on electrical wiring,
installation dimensions, drive requirements, oil requirements, and output shaft
dimensions. The drawings are provided for reference only. Do not use the
drawings for construction.
Available Terminal Shafts and Drive Shafts

The following terminal shafts and drive shafts are available:
Standard—
0.500–36 serrated terminal shaft (0.625–36 serrated for the 20 ft-lb model)
0.625–36 serrated drive shaft
Available (for special applications at additional cost)—

Terminal Shafts—
0.562 / 0.625 D-shaped terminal shaft
0.500–36 serrated terminal shaft with one missing serration
0.500–36 serrated terminal shaft on RH or LH side only
2 Woodward
Keyed Drive Shafts—
0.750–6 splined drive shaft
1.125–48 serrated drive shaft [with PG-style base adapter]
French standard BNA 227 NF-E22-151 0.16-31 drive shaft
RHD6 drive shaft
0.625 keyed drive shaft with 0.625-18 thread
Extended 0.625 keyed drive shaft
UG Governor Similarities
The UG-Actuator uses the same cast-iron case as the UG governor. The
standard UG output shaft, power lever, power piston, and piston link are used in
the actuator. The base is designed to fit any drive designed for a UG governor.
Hydraulic Pump
The UG-Actuator is equipped with a Gerotor pump (3161 governor type). High
speed and low speed pumps are available, depending on the drive speed from
the engine. The pump uses oil from the self-contained UG-Actuator sump to
provide 1172 kPa (170 psi) internal operating pressure.
The direction of rotation is selected by pump housing alignment. The pump

operates in one direction only. The drive uses a maximum of 375 W (0.5 hp). In
some cases the actuator may require an oil cooler to operate at the high end of
the drive speed range.
References
The following publications provide additional information about installation,
operation, and storage of Woodward products. All are available on the
Woodward website (www.woodward.com).
Publication
25071 Oils for Hydraulic Controls
25075 Commercial Preservation Packaging for Storage of Mechanical-
Hydraulic Controls
50516 Governor Linkage for Butterfly Control Valve
37511 UG-Actuator Product Specification
This manual does not attempt to provide information about the electronic control
which determines the position of the UG-Actuator output. This information must
be obtained from the appropriate manual for the electronic control. Contact your
nearest Woodward Distributor or Authorized Independent Service Facility about
repairs.
Woodward 3
Figure 1-2. Outline Drawing of UG-Actuator
4 Woodward
Figure 1-3. Remote Mounted Actuator
Woodward 5
Figure 1-4. Drive Shaft and Terminal Shaft Configurations
6 Woodward
Figure 1-5. Schematic of UG-Actuator
Woodward 7
Chapter 2.
Installation
Introduction
This chapter describes receiving, storage, and installation requirements for the
UG-Actuator.
Use care while handling and installing the UG-Actuator. Be particularly careful to
avoid striking the drive shaft, terminal shaft, or the electrical connector. Abuse
can damage seals, internal parts, and factory adjustments. Do not set the
actuator on its drive shaft.
Receiving
After factory testing and calibration, the UG-Actuator is drained of oil. This leaves
a light film of oil on internal parts to prevent rust. External parts are painted or
coated with a spray lubricant/rust inhibitor.
No internal cleaning or flushing is necessary before installation and operation.

The little oil left in the actuator is clean, multi-viscosity engine oil which will not
contaminate the oil selected to operate the actuator.
Fill the actuator with 1.4 liters (1.5 quarts) of oil selected to match the expected
operating conditions. (If the actuator is a direct replacement for a UG governor,
you may use the same grade and weight of oil that was being used in the
governor.) Use only new, clean oil in the actuator. Do not allow dirt or
contamination to enter the actuator while filling with operating oil. Do not use oil
drained from the UG governor.
Storage
The UG-Actuator may be stored for short periods of time (less than a year) as
received from the factory. For long-term storage (more than a year), storage in an
environment with large temperature changes, humid or corrosive atmosphere, etc.,
or if the actuator is installed on the engine for storage, fill the actuator with oil and
follow preservation packaging instructions in Woodward manual 25075,
Commercial Preservation Packaging for Storage of Mechanical-Hydraulic Controls.
Drive Shaft Rotation

The actuator drive-shaft rotation is one direction only. Rotation, as viewed from
the top of the actuator, must be the same as that of the engine drive when
looking down on the mounting pad.
If the actuator oil pump is rotated in the wrong direction, oil pressure will not be
generated in the actuator.
Be sure engine mounting-pad drive and actuator-drive rotation are

the same. Incorrect drive rotation will cause the actuator to become
inoperative, and may cause actuator damage.
8 Woodward
Figure 2-1. Alignment of Reference Notch and Arrow
Use the following procedure to change the direction of rotation:
1. Remove the four pump-housing screws.
2. Index the pump plate 180 degrees to align the arrow corresponding to the
direction of rotation selected with the reference notch in the base.
3. Replace the four screws, and torque the screws to 16.4–17.5 N·m (145–155
lb-in).
4. Make sure that the actuator drive shaft rotates freely.
Attitude
The UG-Actuator can be installed in a vertical or near vertical position without
affecting its calibration. Do not install more than 45 degrees from vertical. See
the outline drawing for installation instructions and dimensions.
Mounting Dimension
When using the o-ring supplied with the actuator to seal between the actuator
and actuator mounting pad on the engine, the mounting hole should have
dimensions of 82.7–83.2 mm (3.255–3.275 inches) in order to provide the correct
amount of squeeze on the o-ring. The mounting hole must be concentric with the
drive in order to avoid side-loading the actuator drive shaft.
Drive Connection
Make sure the actuator drive shaft turns freely before installing the actuator. The
drive gear or coupling must slip freely into the governor drive of the engine. Do
not apply external force. The drive must be free of binding, side load, or excess
end-play. Improper alignment or fit between the parts can result in excessive
wear or actuator-drive seizure.
Woodward 9
Mount the actuator squarely on the mounting pad. Torque the mounting bolts
evenly. There can be no movement or rocking of the actuator on the engine-
mounting pad.
Remote Actuator Oil Connection

If the UG-Actuator is remotely installed, oil supply is through the side of the base
mounting plate (Figure 1-3). Connect the external pressure supply to one of the
two .250–18 NPTF ports in the base mounting plate. The oil supply line should
be fitted with a 20–25 µm filter. The oil supply pressure must be at least 758 kPa
(110 psi). A pressure of 2758 kPa (400 psi) will be required for 27 J (20 ft-lb) of
output. The remote unit will require 1.9 L/min (0.5 US gal/min) at steady state
and 9.5 L/min (2.5 US gal/min) transient response supply flow.
Connect the return line to the .250–18 NPTF port in the top cover. Do not use the
.125–27 connection in the base during operation. The actuator should be kept
filled with oil for corrosion protection of internal parts.
Control Linkage
The terminal shaft rotates 42 degrees. Use 2/3 of the total rotation between no
load and full load. The additional “overtravel” should be split and used at both
ends to provide maximum fuel when required and to assure shutdown at
minimum-fuel actuator position (see Figure 2-2).
To prevent possible serious injury or loss of life, or damage to the

engine, be sure to allow sufficient overtravel at each end of the
terminal shaft so the actuator can shut down the engine, and also
give maximum fuel when required. Misadjusted linkage could prevent
the actuator from shutting down the engine.
Many control problems are related to the linkage between the actuator and the
engine. Use only first-quality rod ends for the linkage, rod ends that will last
under the nearly constant motion associated with precise speed control. The
linkage must be stiff, not subject to engine-caused vibration. The linkage must be
as light as possible and still maintain the attributes of stiffness. Linkage which is
too heavy can damage the actuator as well as make it difficult to achieve steady
control.
Installed linkages must operate smoothly, be free of binding, and free of lost
motion due to worn parts. If there is a collapsible member in the linkage, be sure
it does not yield each time the actuator moves the linkage rapidly.
Use a linear linkage for most diesel applications. Most gasoline and gas fueled
engines will require a non-linear linkage. See Figures 2-3 and 2-4 for information
on the arrangements of linear and nonlinear connections. Linear linkage moves
the fuel setting shaft in direct proportion to the movement of the actuator output.
Nonlinear fuel arrangement lets the actuator open the fuel setting more at
maximum settings than it does at minimum settings. Woodward application note
50516, Governor Linkage for Butterfly Throttle Valves, provides more information
about non-linear linkage.
Design the linkage so the power output of the engine is proportional to the
position of the actuator output shaft.
10 Woodward
Figure 2-2. Terminal Shaft Travel
Follow the engine manufacturer's instructions on linkage selection, installation,

and adjustment. In almost all cases, the linkage designed for a UG-8 governor
will work with the UG-Actuator. In the case of a direct exchange, make sure that
the linkage is in good condition and the installation of the lever on the actuator is
in the same position as it was on the governor.
Figure 2-3. Linear Linkage Figure 2-4. Nonlinear Linkage
Woodward 11
Oil Supply
Use the information given in Figures 2-5 and 2-6 as a guide in the selection of a
suitable oil. Oil grade selection is based on the operating temperature range of
the actuator. Also use this information to aid in recognizing and correcting
common problems associated with oil used in the actuator. Many operation and
maintenance problems associated with UG-Actuators are directly related to the
selection and condition of the oil in the actuator. Use care in the selection and
make sure that the oil in the actuator is not contaminated.
The oil in the UG-Actuator is both a lubricating and hydraulic oil. It must have a
viscosity index that allows it to perform over the operating temperature range and
it must have the proper blending of additives that cause it to remain stable and
predictable over this range.
The UG-Actuator is designed to give stable operation with most oils, if the fluid
viscosity at the operating temperature is within a 50 to 3000 SUS (Saybolt
Universal Seconds) range (see Figure 2-6). Poor actuator response or instability
is an indication that the oil is too thick or too thin.
Actuator oil must be compatible with seal material, that is, nitrile, polyacrylic, and
fluorocarbon. Many automotive and gas engine oils, industrial lubricating oils,
and other oils of mineral or synthetic origin meet these requirements.
Fill the actuator with about 1.4 liters (1.5 quarts) of oil, to the mark on the oil sight
glass. After the engine is started and the actuator is at operating temperature,
add oil if necessary. Oil must be visible in the glass under all operating
conditions.
Excessive component wear or seizure in the actuator indicates the possibility of:
1. Insufficient lubrication caused by:

an oil that flows slowly when it is cold, especially during start-up;
no oil in the actuator.
2. Contaminated oil caused by:
dirty oil containers;
an actuator exposed to heating and cooling cycles, which created
condensation of water in the oil.
3. Oil not suitable for the operating conditions caused by:
changes in ambient temperature;
an improper oil level which creates foamy, aerated oil.
Operating an actuator continuously beyond the high limit temperature of the oil
will result in oil oxidation. This is identified by varnish or sludge deposits on the
actuator parts. To reduce oil oxidation, lower the actuator operating temperature
with a heat exchanger or other means, or change to an oil more oxidation-
resistant at the operating temperature.

engine, resulting from engine overspeed or a runaway engine, be
sure to use only oil that falls within the 50 to 3000 SUS range. Using
oils outside this range could cause the actuator to be unable to
prevent a runaway engine.
12 Woodward
Oil Maintenance
Replace the actuator oil if it is contaminated, and change it if it is suspected of
contributing to instability. Drain the oil while it is still hot. Flush the actuator with a
clean solvent having some lubricating quality (fuel oil or kerosene) before refilling
with new oil. If drain time is insufficient for the solvent to completely drain or
evaporate, flush the actuator with the same oil it is being refilled with to avoid
dilution and possible contamination of the new oil.
Oil that has been carefully selected to match the operating conditions and is
compatible with actuator components should give long service between oil
changes. Check oil conditions regularly and change oil if any deterioration or
contamination is suspected.
Regularly scheduled oil changes will extend the life of the actuator and improve
actuator operation. Properly selected oil should permit annual oil changes, but
more frequent changes are recommended.
Figure 2-5. Oil Chart
Woodward 13
Figure 2-6. Viscosity Comparisons
EXPLOSION HAZARD—Do not remove covers or connect/disconnect

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
Substitution of components may impair suitability for Class I,

Division 2.
RISQUE D’EXPLOSION—Ne pas enlever les couvercles, ni

raccorder / débrancher les prises électriques, sans vous en
assurez auparavant que le système a bien été mis hors
tension; ou que vous vous situez bien dans une zone non
explosive.
La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I, Division 2.
Due to the hazardous location listings associated with this product,

proper wire type and wiring practices are critical to operation.
Do not connect any cable grounds to “instrument ground”, “control

ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagrams (Figures 2-7a
and 2-7b).
Electrical Connection
The electrical connector on the UG-Actuator is a 3-pin (MS-3102E-14S-7P) plug
connector. The LVDT version has a 10-pin connector (MS-3102E-18-1P or
MS-3102R-18-1P).
14 Woodward
Figure 2-7a. Wiring for a UG-Actuator
Figure 2-7b. Wiring for a UG-Actuator with LVDT
Heat Exchanger Selection

A heat exchanger is available for the UG-Actuator. It consists of a plate mounted
on the front of the actuator. Passages are cut in the plate that allow cooling fluid
to pass through the plate and remove energy from the actuator. The guidelines
for when to use the heat exchanger are not straightforward, and some knowledge
of the installation is required.
The pump on the UG-Actuator generates energy which must be dissipated from
the actuator. Most of the energy is dissipated through the bottom mounting
surface of the actuator . Therefore, the more direct mounting (no gasket) and the
better heat-dissipating mounting surface (wide) will allow the actuator to run at
the lowest temperatures.
Woodward 15
Because of the variability of mounting surfaces, it is difficult to quantify the
maximum drive speed to maintain the actuator oil at a safe temperature to not
break down the oil. Analysis predicts a 0.65 degree C increase in oil temperature
relative to the mounting surface for each increase of 100 rpm on the low speed
pump, and 0.45 degree C per 100 rpm for the high speed pump. Lab tests show
as much as 0.6 degree C per 100 rpm for the high speed pump. This is
complicated by the fact that the mounting temperature will also rise, so the rise in
oil temperature per 100 rpm is actually greater than this. The rise in the mounting
surface temperature depends greatly on the geometry of the mounting surface
itself.
Refer to Figure 2-8 for selection of heat exchanger parameters. The temperature
reduction achieved with the heat exchanger depends on the difference between
the heat exchanger inlet temperature and the temperature of the actuator oil
without the heat exchanger. It also depends on the specific heat of the coolant.
The chart is based upon petroleum oil. It does not depend heavily on supply
pressure of the coolant. Testing at Woodward was done at 138 and 345 kPa (20
and 50 psi), as a guideline.
Overall, to maintain the lowest actuator temperature at a given rpm, use the
thinnest gasket or none at all (seal with an o-ring around pump housing) and
provide the lowest possible coolant temperature to the heat exchanger.
Figure 2-8. UG-Actuator Heat Exchanger
16 Woodward
Chapter 3.
Initial Operation
Before initial operation of the engine equipped with a UG-Actuator, read all of
Chapter 2, Installation Procedures. Make sure that all installation steps have
been correctly accomplished and all linkages are secured and properly attached.
Carefully review the direction of rotation for the actuator oil pump.
Follow this procedure when putting a new or repaired UG-Actuator into service.
1. Check that the actuator is full of the proper type and grade of clean oil.
2. Properly adjust the linkage.

engine, be sure to allow sufficient overtravel at each end of the
terminal shaft so the actuator can shut down the engine, and also
give maximum fuel when required. Misadjusted linkage could prevent
the actuator from shutting down the engine.
3. Select a LOW SPEED setting on the Woodward electronic control to give

low engine speed at initial start up.
Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
4. Follow the engine manufacturer's instructions, and start the engine.
5. Adjust the selected speed setting on the Woodward electronic control as

necessary to bring the engine to rated speed.
6. Obtain system stability as outlined in the electronic control instruction

manual. (If less than the recommended actuator output stroke is used, it
may cause for less than optimum engine stability or response.)
All operating adjustments of the UG-Actuator are made during factory calibration.
Additional adjustment should not be needed.
Woodward 17
Chapter 4.
Principles of Operation
Introduction
This chapter describes the operation of the UG-Actuator. The schematic drawing
in Figure 1-5 illustrates the working relationship of the various parts.
Connecting oil passages between components are simplified for ease in

visualizing the system.
The UG-Actuator contains its own sump.
The UG-Actuator consists of the following basic components:
1. Oil Pump
Gerotor pump. Pump is driven by the actuator drive shaft.
2. Relief Valve
Set to maintain internal operating pressure at 1172 kPa (170 psi).
3. Oil Filter
Filters oil to the pilot valve to prevent contamination of the orifice and
nozzle. Bypass oil flows through the filter, providing a filter-cleaning function.
4. Torque Motor, Torque Motor Beam, Feedback Spring, and Loading

Spring
Used to establish a mechanical position of the pilot valve flapper in
response to the dc current being sent to the actuator.
5. Pilot Valve Plunger

A follower-type valve, which duplicates the movement of the torque-motor
beam, but at a much higher force level, controls flow of oil to and from the
servo. The pressure regulator is used to minimize calibration shifts due to
speed-induced pump pressure changes.
6. Power Piston, Terminal Lever, and Terminal Shaft

The terminal lever converts the linear motion of the differential-type servo
piston to rotary motion of the terminal shaft, which in turn moves the fuel
linkage. The terminal-shaft position is fed back to the torque-motor beam to
provide the proportional control.
Increase in Load or Speed Setting

An increase in load, or speed setting, causes an increase in control current from
the electronic control to the torque motor. This, in turn, causes an increase in the
torque-motor force, tending to lower the centering adjustment end of the torque
motor beam. The flow of oil through the nozzle is decreased, which increases
pressure on the top side of the differential power land. Pressure above the
differential power land then moves the pilot-valve plunger down, or allows the
plunger to follow the torque-motor beam as if they were one piece. Pressure oil is
now directed to the underside of the servo piston, causing it to move upward,
which rotates the terminal lever and terminal shaft in the increase-fuel direction.
18 Woodward
As the terminal shaft rotates, the range adjustment and feedback linkage
increases the feedback spring force, and cause the torque-motor beam to move
away from the nozzle. As flow through the nozzle is less restricted, pressure
decreases on the top side of the differential power land to start moving the pilot-
valve plunger up. The terminal shaft and pilot-valve plunger movement continues
until the increase in feedback-spring force equals the increase in force seen in
the torque motor. When the pilot-valve control land is centered, all movement
stops at the new position required to run the engine at the increased load or
speed setting.
Decrease in Load or Speed Setting

A decrease in load or speed setting causes a decrease in control current from
the electronic control to the torque motor. This, in turn, causes a decrease in
torque motor force, and raises the centering adjustment of the torque motor
beam. The pilot valve follows the beam and uncovers the control port. Oil trapped
under the servo piston escapes to drain, causing the servo piston to move
downward and the terminal shaft to rotate in the decrease-fuel direction.
As the terminal shaft rotates, the range adjustment and feedback linkage decrease
the feedback-spring force. The terminal shaft rotates until the decrease in spring
force equals the decrease in force in the torque motor, and the pilot-valve plunger
is centered. This stops the servo piston and the actuator shaft in the new position
needed to run the engine at the decreased load or speed setting.
Loss of Control Voltage

Upon loss of control voltage, the actuator terminal shaft goes to minimum fuel,
thus offering a safety feature.
With loss of control voltage, there is no current sent to the torque motor and no
magnetic force generated. The torque motor and attached beam and the force of
the loading spring causes the center adjustment to raise. The pilot valve follows,
keeping the control port uncovered. Trapped oil escapes to drain, and the servo
piston moves down until it reaches minimum fuel position.
Woodward 19
Chapter 5.
Product Support and Service Options
Product Support Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email
(EngineHelpDesk@Woodward.com) with detailed information on the
product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone
or return email.
5. If the issue cannot be resolved, you can select a further course of action to
pursue based on the available services listed in this chapter.
OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
 A Full-Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on
Woodward's behalf. Service (not new unit sales) is an AISF's primary
mission.
 A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at

www.woodward.com/directory.
Product Service Options

Depending on the type of product, the following options for servicing Woodward
products may be available through your local Full-Service Distributor or the OEM
or Packager of the equipment system.
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture
20 Woodward
Replacement/Exchange: Replacement/Exchange is a premium program
designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic products in the field. This
program offers you repair service for your products with the advantage of
knowing in advance what the cost will be.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option, with the exception that the unit will be returned to you in “like-
new” condition. This option is applicable to mechanical products only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
 return number;
 name and location where the control is installed;
 name and phone number of contact person;
 complete Woodward part number(s) and serial number(s);
 description of the problem;
 instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:
 protective caps on any connectors;
 antistatic protective bags on all electronic modules;
 packing materials that will not damage the surface of the unit;
 at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
 a packing carton with double walls;
 a strong tape around the outside of the carton for increased strength.
To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Replacement Parts
When ordering replacement parts for controls, include the following information:
 the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
 the unit serial number, which is also on the nameplate.
Woodward 21
Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our
products. For these services, you can contact the Distributor by telephone or by
email.
 Technical Support
 Product Training
 Field Service
Technical Support is available from your equipment system supplier, your local
Full-Service Distributor, or from many of Woodward’s worldwide locations,
depending upon the product and application. This service can assist you with
technical questions or problem solving during the normal business hours of the
Woodward location you contact.
Product Training is available as standard classes at many Distributor locations.

Customized classes are also available, which can be tailored to your needs and
held at one of our Distributor locations or at your site. This training, conducted by
experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product

and location, from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the non-
Woodward equipment with which our products interface.
For information on these services, please contact one of the Full-Service

Distributors listed at www.woodward.com/directory.
Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service
facility, please consult our worldwide directory published at
www.woodward.com/directory.
You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.
Products Used In Products Used In Products Used In

Electrical Power Systems Engine Systems Industrial Turbomachinery
Systems
Facility---------------- Phone Number Facility---------------- Phone Number Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany: Germany------- +49 (711) 78954-510 India --------------- +91 (129) 4097100
Kempen ---- +49 (0) 21 52 14 51 India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191
Stuttgart-- +49 (711) 78954-510 Japan -------------- +81 (43) 213-2191 Korea -------------- +82 (51) 636-7080
India --------------- +91 (129) 4097100 Korea -------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111
Japan -------------- +81 (43) 213-2191 The Netherlands - +31 (23) 5661111 Poland--------------- +48 12 295 13 00
Korea -------------- +82 (51) 636-7080 United States ---- +1 (970) 482-5811 United States ---- +1 (970) 482-5811
Poland--------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811
For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.
22 Woodward
Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Manufacturer
Engine Model Number
Number of Cylinders
Type of Fuel (gas, gaseous, diesel,
dual-fuel, etc.)
Power Output Rating
Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
Symptoms
Description
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
Woodward 23
UG-Actuator Control Specifications

Control Qualities
Hysteresis Within 3% of maximum travel when measured
over full 42 degree travel. Within 0.5% of
maximum travel when measured over 4% of full
travel at 1 Hz.
Temperature Drift Nominally ±1 degree per 42 ºC (108 ºF)
Time Constant 70 to 90 ms for 50 mA step with 1172 kPa (170
psi) actuator oil pressure
Linearity Within 2.5% of full 42 degree output travel
Work Output 27.7 Nm (20.4 lb-ft) stalled torque; 20 J (15 ft-
lb) of work over 42 degrees. The UG-Actuator
operates with 1172 kPa (170 psi) internal
hydraulic pressure.
Pump Gerotor (3161 pump). Relief valve set at 1172
kPa (170 psi).
Output Shaft 0.500-36 inch serrated standard. In same
location relative to drive as UG governor. (See
Chapter 1 for additional optional shafts.)
Drive Shaft 0.625-36 serration standard. (See Chapter 1 for
additional optional shafts.)
Weight 16 kg (36 lb), dry weight
Vibration Resistance Vibration tested to US MIL-STD 810C, Curve D
(10 G to 2000 Hz; in Y-axis, parallel to drive
shaft, 8 G maximum)
Drive/Hydraulic Specifications
Drive Speed and Rotation Actuator available with either high or low speed
pump. High speed pump: 600 to 1500 rpm. Low
speed pump: 375 to 1100 rpm. Drive operates in
one direction only.
Drive Power Requirement Drive will use a maximum of 375 W (0.5 hp)
Hydraulic Supply Self contained sump, 1.4 liter (1.5 quart)
capacity. See Woodward manual 25071, Oils for
Hydraulic Controls, for specific
recommendations. In most cases, the same type
and weight of oils used in the engine can be
used in the governor.
Ambient Temperature Range +29 to +93 °C (+20 to +200 °F)
Operating Temperature +29 to +93 °C (+20 to +200 °F), within the limits
of the oil being used in the governor
Electrical Specifications
Electrical Connector 3 pin, US MIL-STD 3102E-14S-7P, located in
cover
LVDT: 10-pin, US MIL-STD 3102E-18-1P or MS
3102R-18-1P
Coil Resistance 23–26  at 20 °C
Calibration 1–2 degrees at 20 mA, 37 ±2 degrees additional
travel from 20 mA to 160 mA. Reaches
maximum fuel at less than 200 mA.
24 Woodward
Revision History
Changes in Revision H—
 Updated Regulatory Compliance Information
Woodward 25
We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please reference publication 37512H.
PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058
Email and Website—www.woodward.com
Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
December 2015 SERVICE MANUAL for Eastern Refinery Limited. Pub. No. 99089-40100
Printed in Japan Pub. No. 99089-40100

99089-40100 00

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SERVICE MANUAL December 2015

Pub. No. 99089-40100

for Eastern Refinery Limited.

HOW TO USE THIS MANUAL

Brief summary of the system used in compiling this service manual:

Terms used in this manual

Abbreviations and Standards

Keep Flames Away Be Alert for Leaking Fuel, Oil, or Exhaust

Stay Away From Rotating and Moving Parts

Install Protective Covers Over Rotating Lockout and Tagout

Work tion and maintenance. Lockout and tagout are effec-

Keep away from the rotating parts Use

result. ing tool inserted or left in the turning condition, it can

Prevention of Exhaust Gas Poi- Fall Prevention

If the engine is installed in an engine weight. To lift the engine,

erator, do not operate in a poorly ventilated place such center of gravity.

loss. high on the engine, use a ladder, footing, and others to

Always Prepare a Stable Footing

Be Careful When Handling Fuel, Burn Protection

Burn Prevention When Changing Oil

Battery Safety Precautions When Abnormality Occurs

Be Careful When Handling Battery Do Not Add Coolant Immediately After a

Do Not Tamper Engine Break-in

Prohibition of Continuous Low-Load Opera- Obey Safety Rules at Work Site

accumulating. nals to communicate among workers.

Pre-cleaner is to be properly maintained Pay Attention to Engine Room Ventilation

Maintenance of Warning Labels

Common Warning Labels

Points on Disassembling and Assembling

Chapter 2 SERVICE DATA

Chapter 3 SERVICE TOOLS

Chapter 4 PERIODIC MAINTENANCE SCHEDULE

Chapter 5 PREPARATION FOR DISASSEMBLY

Chapter 6 DISASSEMBLY OF BASIC ENGINE

Chapter 7 INSPECTION AND REPAIR OF BASIC ENGINE

Chapter 9 FUEL SYSTEM

Chapter 10 LUBRICATION SYSTEM

Chapter 11 COOLING SYSTEM

Chapter 12 INLET AND EXHAUST SYSTEMS

Chapter 13 AIR START SYSTEM

Chapter 14 ADJUSTMENT AND OPERATION

Secondary oil filter

Starting air inlet

Engine oil drain

Left Side View

Air cleaner Oil level gage Fuel filter

Secondary Fuel return port

Starting air Strainer Lube oil inlet(From L/O tank)

Right Side View

Exhaust gas outlet

Main terminarl box

Injection pump Injection nozzle Injection pump

Fuel secondary filter

Outline of Fuel System (1CV-Type Injection Pump)

Outline of Lubrication System

2.3 Outline of Cooling System

Outline of Cooling System

2.4 Outline of Inlet and Exhaust System

2.5 Outline of air start system

Pilot air pipe

Outline of Air Start System

3. Engine serial number

Engine serial number