4d94e17 Be2 1

4D94E17-BE2
00-1
GENERAL
CONTENTS
1. GENERAL............................................................................................................ 1-1
2. TROUBLESHOOTING ......................................................................................... 2-1
3. INSPECTION AND ADJUSTMENT ..................................................................... 3-1
4. ENGINE BODY .................................................................................................... 4-1
5. LUBRICATION SYSTEM ..................................................................................... 5-1
6. COOLING SYSTEM ............................................................................................. 6-1
7. FUEL INJECTION PUMP, GOVERNOR ............................................................. 7-1
8. STARTING MOTOR............................................................................................. 8-1
9. ALTERNATOR..................................................................................................... 9-1
10. SPECIAL SERVICE TOOLS.............................................................................. 10-1
11. SERVICE STANDARDS .................................................................................... 11-1
00-2 4D94LE, 4D98E

1. GENERAL
1. GENERAL
1-1 Specifications.......................................................................................................................................... 1-2

1-2 Fuel oil, lubricating oil and cooling water ................................................................................................ 1-3
1-3 Engine performance curve...................................................................................................................... 1-4
1-4 Engine external views ............................................................................................................................. 1-6
1-5 Structural description .............................................................................................................................. 1-8
1-6 How to read this manual ....................................................................................................................... 1-10
1-7 Precautions for service work................................................................................................................. 1-12
1-8 Tightening torques for standard bolts and nuts .................................................................................... 1-13
4D94LE, 4D98E 1-1

1. GENERAL
1-1 Specifications
Engine name — 4D94LE 4D98E
Engine specification class — For standard forklift truck
Type — Vertical, in-line, 4-cycle diesel engine

Swirl chamber type, Special swirl chamber
Combustion chamber —
without turbocharger type, without turbocharger
Intake system Naturally aspirated
Number of cylinders — 4
Cylinder bore x stroke mm 94 x 110 98 x 110
Displacement l 3.053 3.318
rpm 2,200 2,450
HP SAE 45.8 59.2

Rated output (Net)
kW 34.2 44.1
PS 46.5 60.0
Max. speed at no load (Bare engine) rpm 2,450 ± 25 2,725 ± 25
Low idle speed (Bare engine) rpm 810 ± 25 845 ± 25
Dry engine weight* kg 225
Power take-off position — Flywheel side
Direction of rotation — Counterclockwise (viewed from flywheel)
Cooling system — Radiator

Lubrication system — Forced lubrication with trochoid pump
• Oil pressure during normal operation MPa {kgf/cm2} 0.29 – 0.39 {3.0 – 4.0}
• Oil pressure during no-load operation MPa {kgf/cm2} Min. 0.13 {1.3}
Starting system Electric starting system
• Starting motor DC12V, 2.3kW
—
• Alternator DC12V, 40A
• Recommended battery capacity 12V, 622CCA (Cold cranking current)
Engine dimensions*
• Overall length mm 713
• Overall width mm 522
• Overall height mm 755
7.5 / 5.5
Lubricant capacity (oil pan) l
(Upper / Lower limit of oil level gauge)
Cooling water capacity (engine only) l 4.2
*: Value when radiator, silencer, and air cleaner are not installed.
1-2 4D94LE, 4D98E

1. GENERAL
1-2 Fuel oil, lubricating oil and cooling water

Use proper fuel oil, lubricating oil and cooling water and change them according the Operation and Mainte-
nance Manual.
4D94LE, 4D98E 1-3

1. GENERAL
1-3 Engine performance curve

4D94LE [Applicable machine: FD20/25/30-17]
Rated horsepower: 34.2 kW {45.8 HP}/2,200 rpm (Net)
Maximum torque: 162 Nm {16.5 kgf•m}/1,500 rpm (Net)
N·m
225
200 162 N·m/1,500 rpm
175 Torque kW
Torque
150 55
125 50
100 45
34.2 kW/2,200 rpm

75 40
g/kWh
Fuel consumption
320 35
Output
300 30
Output
280 25
260 Fuel consumption 20
240 15
220 10
200 5
Engine Speed rpm
1-4 4D94LE, 4D98E

1. GENERAL
4D98E [Applicable machine: FD20H/25H/30H/35A-17]

Rated horsepower: 44.1 kW {59.2 HP}/2,450 rpm (Net)
Maximum torque: 183 Nm {18.7 kgf•m}/1,500 rpm (Net)
N·m
225
183 Nm/1,500 rpm
200 Torque
175 kW
Torque
150 55
44.1 kW/2,450 rpm

125 50
100 45
75 40
g/kWh
320
Output 35
Output
Fuel consumption
300 30
280 25
260 20
Fuel consumption
240 15
220 10
200 5
Engine Speed rpm
4D94LE, 4D98E 1-5

1. GENERAL
1-4 Engine external views

4D94LE/98E
1) Starting motor 7) Fuel injection pump

2) Exhaust manifold 8) Oil pan
3) Alternator 9) Oil filter
4) Radiator fan 10) Flywheel housing
5) Intake manifold 11) Flywheel
6) Fuel filter
1-6 4D94LE, 4D98E

1. GENERAL
12) Crankshaft pulley
4D94LE, 4D98E 1-7

1. GENERAL
1-5 Structural description

4D94LE/98E
1) Intake manifold 9) Tappet

2) Fuel injection nozzle 10) Camshaft
3) Preheater coil 11) Engine oil pan
4) Rocker arm housing 12) Oil strainer
5) Rocker arm 13) Connecting rod cap bolt
6) Exhaust manifold 14) Engine oil filter (oil cooler: option)
7) Piston 15) Fuel injection pump
8) Cylinder block
1-8 4D94LE, 4D98E

1. GENERAL
16) Water pump 20) Flywheel

17) Thermostat 21) Crankshaft
18) Cylinder head gasket 22) Gear case (equipped with oil pump)
19) Cylinder head 23) Gear
4D94LE, 4D98E 1-9

1. GENERAL
1-6 How to read this manual

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

(2-1) An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section
as required for easy understanding of the mounted states of the components.
(2-2) For the removal/installation of each part, the procedure is shown with the procedural step No. in the
illustration.
(2-3) Precautions and key points for disassembly and reassembly of parts are described as Points. In the
explanation for each point, detailed operation method, information, standard and precautions are
described.
Description Example
• Illustration
a The job contents are described in the disassembly procedure for Nos. not shown in the illustra-
• Disassembly procedure • Operation Points

(1) Follow steps (1) to (12) of the cylinder head Disassemble: Service point for removal
disassembly procedure. Reassemble: Service point for installation
(2) Remove the cooling water pump. Disassemble-Reassemble: Service point
(3) Remove the crankshaft pulley. (Point 1) required in both removal and installation.
Operation point to be explained on a later page.
1-10 4D94LE, 4D98E

1. GENERAL
• Contents omitted in this manual

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

k Instruction whose negligence is very likely to cause an accident. Always observe it.
Standard: Allowable range for inspection and adjustment.
Limit: The maximum or minimum value that must be satisfied during inspection or adjustment.
(4) Abbreviations
Abbreviation Meaning
Ass’y assembly
Sub-Ass’y sub-assembly
A.T.D.C. after top dead center

B.T.D.C. before top dead center
STD Standard
IN Intake
EX Exhaust
T.D.C. top dead center
B.D.C. bottom dead center
OS oversize
US undersize
rpm revolutions per minute

HP output (horsepower)
3 Bolt/nut tightening torque
4D94LE, 4D98E 1-11

1. GENERAL
1-7 Precautions for service work

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

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

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

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

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

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

(7-1) Use measuring instruments for adjustment to the specified service standards.
1-12 4D94LE, 4D98E

1. GENERAL
1-8 Tightening torques for standard bolts and nuts

(Lubricating oil not applied)
(Unit: Nm {kgf•m})
Nominal thread
Item Tightening torque Remarks
diameter x pitch
M6 x 1 mm 9.8 – 11.8 {1.0 – 1.2} 1) When tightening aluminum
parts, apply 80% of torque
M8 x 1.25 mm 22.6 – 28.4 {2.3 – 2.9} shown at left
M10 x 1.5 mm 44.1 – 53.9 {4.5 – 5.5} 2) When tightening 4T bolt and
Hexagon bolt (7T)/nut lock nut, apply 60% of torque
M12 x 1.75 mm 78.5 – 98.1 {8.0 – 10} shown at left
M14 x 1.5 mm 127 – 147 {13 – 15}
M16 x 1.5 mm 216 – 235 {22 – 24}

1/8 9.8 {1.0}
1/4 19.6 {2.0}

PT plug
3/8 29.4 {3.0}
1/2 58.8 {6.0}
M8 12.7 – 16.7 {1.3 – 1.7}
M10 19.6 – 34.3 {2.0 – 3.5}
Pipe joint bolt M12 24.5 – 34.3 {2.5 – 3.5}
M14 39.2 – 49.0 {4.0 – 5.0}
M16 49.0 – 65.8 {5.0 – 6.0}
Note: Never apply lubricating oil to the bolt thread or seat surface.
4D94LE, 4D98E 1-13

2. TROUBLESHOOTING
2. TROUBLESHOOTING
2-1 Quick reference table for troubleshooting ............................................................................................... 2-2

2-2 Troubleshooting by measuring compression pressure ........................................................................... 2-6
4D94LE, 4D98E 2-1

2. TROUBLESHOOTING
2-1 Quick reference table for troubleshooting

The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs,
take corrective action before it developes into a serious problem so as not to shorten the engine service life.
2-2 4D94LE, 4D98E

2. TROUBLESHOOTING
3-3)
4-2 (6))
4-2 (2)-
4-2 (2)-
4-4 (5))
4-4 (4))
4-4 (5))
4-4 (5))
4-4 (4))
4-3 (4))
4-2 (5))
3-8)
3-3)
3-8 (1))
3-8 (1))
3-2)
3-2)
3-6 (1))
4D94LE, 4D98E 2-3

2. TROUBLESHOOTING
Intake/Exhaust gas
system
2-4 4D94LE, 4D98E

2. TROUBLESHOOTING
1-2 (2))
5-5)
1, 1-2)
3, 3-5)
3, 3-5)
1, 1-2)
3, 3-4)
3, 3-7)
4D94LE, 4D98E 2-5

2. TROUBLESHOOTING
2-2 Troubleshooting by measuring compression pressure

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

1) After warming up the engine, remove the
fuel injection pipes and nozzles from the
cylinder to be measured.
2) Crank the engine before installing the
compression gauge adapter.
a1. Perform cranking with the regulator
handle at the stop position (no injec-
tion state).
a2. See 10-2-18 in Chapter 10 for the
compression gauge adapter.
3) Install the compression gauge and
compression gauge adapter at the cylinder
to be measured.
a Never forget to install a gasket at the tip
end of the adapter.
4) With the engine set to the same state as in 1) Compression gauge
2) a1, crank the engine by the starting
motor until the compression gauge reading
is stabilized.
(2) Standard compression pressure

[Engine compression pressure list (reference value)]
Compression pressure (MPa {kgf/cm2}) at 250 rpm Dispersion among cylinders

Engine model
Standard Limit (MPa {kgf/cm2})
4D94LE, 4D98E 2.84 – 3.04 {29 – 31} 2.35 {24} 0.2 – 0.3 {2 – 3}
2-6 4D94LE, 4D98E

2. TROUBLESHOOTING
(3) Engine speed and compression pressure (reference)
(4) Measured value and troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
No. Item Cause Corrective action
Clogged element Clean the element.
1 Air cleaner element Broken element

Replace the element
Defect at element seal portion
2 Valve clearance Excessive or no clearance Adjust the valve clearance.

(See 3-3 in Chapter 3.)
Adjust the valve clearance.
3 Valve timing Incorrect valve clearance
(See 3-3 in Chapter 3.)
Replace the gasket.
4 Cylinder head gasket Gas leak from gasket
Retighten the cylinder head bolts to the
specified torque. (See 4-2 (2) B in Chapter 4.)
Intake/exhaust valve Sticking of valve Replace the intake/exhaust valve.
5
Gas leakage caused by wear of Lap the valve seat.
Valve seat valve seat or foreign matter in valve (See 4-2 (6) in Chapter 4.)
Piston
Perform honing and use an oversized part.
6 Piston ring Gas leak due to scratching or wear
(See 4-4 (5)-(5-1), (5-4) and (6) in Chapter 4.)
Cylinder
4D94LE, 4D98E 2-7

3. INSPECTION AND ADJUSTMENT
3-1 Inspecting water leak from cooling water system and radiator ............................................................... 3-2
3-2 Fan belt tension inspection and adjustment ........................................................................................... 3-3
3-3 Adjusting the valve clearance ................................................................................................................. 3-4
3-4 Testing injection pressure and spraying condition of fuel injection nozzle ............................................. 3-5
3-5 Testing and adjusting of fuel injection timing .......................................................................................... 3-9
3-6 Sensor inspection ................................................................................................................................. 3-10
3-7 Battery inspection ................................................................................................................................. 3-11
3-8 Adjusting operation ............................................................................................................................... 3-13
3-9 Long storage......................................................................................................................................... 3-13
3-10 Periodic maintenance schedule............................................................................................................ 3-14
4D94LE, 4D98E 3-1

3-1 Inspecting water leak from cooling water system and radiator
(1) Water leak check in cooling water system Water leak check in cooling water system
1) Fill cooling water to the normal level in the
radiator, and install the cap tester on the
radiator.
2) Operate the manual pump to set the
pressure to 88.3 ± 14.7 kPa {0.9 ± 0.15 kgf/
cm 2 }. If the cap tester pressure gauge
reading drops then, water is leaking from
the cooling water system. Check the water
leaking point.
1
1) Cap tester YE0360
(2) Radiator cap inspection

Install the radiator cap on the cap tester. Set the Radiator cap inspection
tester pressure to 88.3 ± 14.7 kPa {0.9 ± 0.15
kgf/cm2} and see that the cap is opened. If the
cap does not open, replace the cap since it is
abnormal.
2) Radiator cap
2
YE0361
3-2 4D94LE, 4D98E

3-2 Fan belt tension inspection and adjustment

V-belt tension
10 – 14 mm/98 N {10 kgf}
Standard
(8 – 12 mm in initial state) 98N {10kg}
Push the center of the V belt between the alter-

nator and cooling water pump with a finger. The A
V-belt tension is normal if the deflection is 10 to
14 mm. If not, adjust the V-belt tension by the
alternator adjuster. 2
1
1) Cooling water pump

3
2) Alternator
YE0362-A
4) Adjuster
5) Bar (for adjusting Tension adjustment
V-belt tension) 5
6) Alternator
6
YE0363
4D94LE, 4D98E 3-3

3-3 Adjusting the valve clearance

Valve clearance adjustment
Standard 0.15 – 0.25 mm
Make adjustment when the engine is cold.
(1) Set the piston in the cylinder to be adjusted

to the compression T.D.C. (Position where
both intake and exhaust valves are closed)
(2) Loosen the lock nut and adjusting screw,
and check the valve cap for any inclination,
entrapped dirt or wear.
(3) Insert a 0.2 mm thickness gauge between
YE0364
the rocker arm and valve cap, and tighten
the adjusting screw to adjust the valve clear-
ance.
(4) Apply oil to the contact between the adjust- Valve clearance
ing screw and push rod. 2
1
3
YE0365
a If the valve cap head portion is worn,

replace the cap with a new one.
a See that each valve cap is fully covering
the intake/exhaust valve head.
1) Valve clearance
2) Adjusting screw
3) Lock nut
4) Valve cap
3-4 4D94LE, 4D98E

3-4 Testing injection pressure and spraying condition of fuel

injection nozzle
k When performing the injection test of the fuel injection nozzle, put on protective goggles. Do not put your
hand over the nozzle. Since the oil spouting out of the nozzle has very high pressure, it can blind and injure
you.
(1) Disassembly procedure

Perform disassembly steps and in Chapter
4, 4-2, (2).
[1] Loosen the nut and remove the nipple (for
overflow).
[2] Grip the body of the nozzle holder in a vice,
loosen the retaining nut, and remove the
nozzle.
1) Body
2) Retaining nut
3) Spacer
4) Push rod
5) Spring
6) Adjustment shim
7) Nozzle
(2) Assembly: Carry out assembly in the reverse
3 Tightening torque:
order to disassembly.
39.2 Nm {4.0 kgf•m}
(3) Point
1) Apply pads to the vice so that the body of YE1001
the nozzle holder will not be damaged.
2) Do not grip the retaining nut but grip the
body of the noz zle holder to pr ev ent
deformation.
(4) Testing and measuring parts

i) Remove the nozzle from the engine and
install it to the nozzle tester to check the
injection pressure and spraying condition.
ii) If the nozzle has any fault, disassemble,
clean, and reassemble it, and then install it
to the nozzle tester and adjust it.
4D94LE, 4D98E 3-5

iii) Procedure for testing nozzle tester

1) Install the fuel injection valve to the
tester and operate the lever to test.
2) Read the injection pressure indicated
by the meter just before injection starts.
Operate the lever at a rate of about 1
time/second.
3) Judge the spraying condition visually.
Change the operating rate of the lever
from 1 time/second to 5 – 6 times/
second.
4) Use clean fuel and filter for the test.
1) Fuel injection nozzle

2) Nozzle tester
k Never direct the spray at a human body. The pressure of the fuel injected through the nozzle is so
high that the fuel can break and injure the human skin.
k Do not direct the spray at a fire. The atomized fuel catches fire easily and can cause a fire and a
burn.
iv) Adjusting injection pressure

1) Standard value: 11.8 – 13.2 MPa {120 – 135 kgf/cm2}
2) Adjust the injection pressure with the adjustment shim.
If a shim 0.1 mm thick is added, the injection pressure rises by 1.2 – 2.2 MPa {12 – 22 kgf/cm2}.
3) Shims of the following thickness are prepared. Be sure to check the thickness of each shim with a
micrometer before using.
Shim thickness: 0.1, 0.2, 0.3, 0.4, 0.5, 0.52, 0.54, 0.56, 0.58, 0.8 mm
1) Nozzle holder body 4) Acceptable

2) Adjustment shim 5) Rejected
3) Nozzle spring
3-6 4D94LE, 4D98E

v) Criteria for spraying condition

1) Oil-tightness test
Keep the pressure 1.96 MPa {20 kgf/cm2} below the standard value. Under this condition, check
that the fuel does not drip within 10 seconds.
2) Spray test
Change the operating speed of the lever to check the spraying condition. Even if the fuel spouts
out in a line when the lever speed is about 1 time/second, if the fuel is atomized when the lever
speed is 5 – 6 times/second, the nozzle is normal.
Use the following examples to judge the spraying condition of the nozzle.
Examples of spraying conditions to judge performance of nozzle and nozzle holder assembly
Since the needle has flat cuts (F cuts), the fuel is sprayed in strings along the flat cuts. This does not indicate a
trouble.
Judgment
A B C D E
Item
Example of
form of spray
Movement of
pressure
gauge pointer
Vibrates continu- Same as A. Stops at about Rises to cracking Does not rise at
ously at about cracking pres- pressure but low- all when tester
cracking pressure and does not ers remarkably. handle is oper-
sure. vibrate. ated.
Fuel is atomized
but does not indi- Fuel spouts out in
Spray is almost Spray is extremely Fuel drips (spouts
Form of spray cate pulsation of line and drips
even. uneven. out in line).
needle (looks like remarkably.
burner).
1) Usually, carbon 1) Much carbon is 1) Seat is dam- 1) Needle is stuck.

is sticking to sticking to tip of aged. 2) Seat is
nozzle tip. nozzle. 2) Fine grain is extremely dam-
2) Needle tip is 2) Fuel may be caught in seat. aged or worn.
Possible damaged or dirty. 3) Seat is 3) Foreign matter
causes of (Normal) broken, extremely worn. is caught in
trouble although very seat.
rare. 4) Internal parts of
nozzle holder
are worn or bro-
ken.
4D94LE, 4D98E 3-7

vi) Cleaning nozzle

1) Clean the periphery of the nozzle body, taking care not to damage the needle.
2) Pull out the needle and clean it, taking care not to damage it. Do not use a hard metallic tool.
3) Check that the needle is free from a bruise, damage, corrosion, wear, etc. In particular, check the
stem and seat of the needle carefully.
4) Clean the needle thoroughly and set it in the nozzle body. Slant the nozzle body to 60° and pull out
the needle about 1/3. At this time, check that the needle slides down by itself. Turn the needle and
check 2 – 3 times.
(Needle with F-cuts)
1) Needle
2) Body
3) Throttle type (F cuts)
3-8 4D94LE, 4D98E

3-5 Testing and adjusting of fuel injection timing

(1) Put the wrench on the bolt of the crankshaft
pulley in front of engine. Rotate the crank-
shaft clockwise to match the timing mark of
the crankshaft pulley with “O” (which is the
mark of TDC) on the timing scale of the gear
case cover.
(2) Remove center bolt (1) and seal washer

from rear of the fuel injection pump.
(3) Install the dial indicator to timing tool (2).

(1)
(4) Install timing tool (2) to the hole of the center
bolt. This indicates the lift of the plunger of
the fuel injection pump. 0001784
(5) Rotate the crankshaft counterclockwise

about 25°. Then, rotate clockwise. The dial
indicator pointer moves until first 10°, and
20
then stops. After rotating about 25°, rotate a
30
10
40
little clockwise and counterclockwise and
check that dial indicator pointer does not
50
move. (2)
90
60
80
70
(6) Set the dial indicator pointer to “0”.
(7) Rotate the crankshaft clockwise to match

the timing mark of the crankshaft pulley with
the mark at ATDC 4° or 8.5° on the timing
scale of the gear case cover.
4D94LE: ATDC 4° 0001753A-A
4D98E: ATDC 8.5°
(8) If the injection timing is proper, the dial indi-

cator reads 0.97 – 1.03 mm.
(9) If the injection timing is improper, loosen the

three mounting nuts of the fuel injection
pump and the bolts fixing the L-brackets at
the bottom and rear of the fuel injection
pump. Rotate the fuel injection pump so that
the dial indicator reads a proper value.
a If the fuel injection pump is rotated away
from the engine, the injection timing is
advanced. If it is rotated nearer to the (2)
engine, the injection timing is delayed.
0
(10)When a proper value is obtained, tighten the 90
10
fuel injection pump mounting nuts and L- 80

20
bracket bolts. 70
30
60
(11)Remove timing tool (2) and dial indicator. 50
40
Install center bolt (1) and seal washer to the 0001754A-A
hole of the fuel injection pump and tighten

them.
4D94LE, 4D98E 3-9

3-6 Sensor inspection

(1) Thermostat Inspection
1) Using an external heat source, increase the
water temperature slowly. 1
2) If the thermostat starts opening at 71°C and

opens fully at 85°C, it is normal.
2
YE0375
(2) Oil pressure switch

Disconnect the connector from the oil pressure
switch. Keep the voltammeter probes in contact
with the switch terminal and cylinder block while
operating the engine. It is abnormal if circuit is
closed.
1) Thermometer
2) Thermostat
3) Cover
4) Gasket
5) Thermostat
6) Housing Continuity test
7) Tester probes
8) Cylinder block
7
(flywheel side)
8
YE0378-A
3-10 4D94LE, 4D98E

3-7 Battery inspection

(1) Battery structure
2 3
1) Battery case 4
2) Terminal
3) Cap
4) Cover 5
5) Cathode plate 6
6) Separator
1 7
7) Glass mat
8) Anode plate
8
YE0379
(2) Battery inspection

1) Electrolyte level
Add distilled water to the upper limit if the
level is low.
9) Upper limit
10) Lower limit 9
11) OK 10
12) Too low
13) Excessive
14) Electrolyte level 11 12 13
15) Battery tester
14
YE0380
Battery charge measurement with battery tester

2) Battery charge
Use a battery tester or hydrometer and
check the battery condition. If the battery is
discharged, recharge it.
• Measurement with a battery tester
When checking the battery with the bat-
tery tester, connect the red clip of the
tester to the battery positive (+) terminal
and black clip to the battery negative (–)
terminal by pinching them securely, and
judge the battery charge level from the
indicator position.
Green zone: Normal
Yellow zone: Slightly discharged
Red zone: Defective or much
15
discharged
YE0381
4D94LE, 4D98E 3-11

• Measurement with hydrometer Battery charge measurement with a hydrometer

When using a hydrometer, the mea-
sured specific gravity must be corrected
according to the temperature at the time
of measurement. The specific gravity of
battery electrolyte is defined with 20°C
as the standard. Since the specific grav-
ity increases or decreases by 0.0007 1
when the temperature varies by 1°C,
correct the value according to the equa-
tion below.
S20 = St + 0.0007 (t – 20)
Electrolyte temperature
at measurement
Specific gravity at measurement

YE0382
Hydrometer structure
Converted specific gravity at 20°C
2
Specific gravity and remaining
battery charge 3
Discharged
Specific Remaining
quantity of
gravity charge
electricity 4
(20°C) (%)
(%)
1.260 0 100
YE0383
1.210 25 75
1.160 50 50
1) Float 3) Glass tube
1.110 75 25
2) Rubber bulb 4) Float
1.060 100 0
How to read hydrometer
3) Terminals
Clean if corroded or soiled.
4) Mounting bracket
Repair or replace it if corroded.
Retighten if loosened.
5) Battery appearance
Replace the battery if cracked or deformed.
Clean with fresh water if contaminated.
YE0384
3-12 4D94LE, 4D98E

3-8 Adjusting operation

Perform adjusting operation as follows after the maintenance job:
(1) Supply the fuel oil, lubricating oil and cooling water.
a Check the levels of the lubricating oil and cooling water again after test running (for about 5 minutes)
and add as required.
(2) Start the engine, and carry out idling at a low revolution (700 to 900 rpm) for a few minutes.
(3) Run in the engine for about five minutes at the rated revolution (no-load). Check any water, fuel or oil leak
and existence of abnormal vibration or noise. Also check the oil pressure, cooling water temperature and
exhaust gas color.
(4) Adjust the no-load minimum and maximum revolutions according to the specifications.
(5) Perform loaded operation as required.
3-9 Long storage

Observe the following instructions when the engine is to be stored for a long period without operation:
(1) Always drain cooling water in a cold season or before a long storage. (This is unnecessary when antifreeze
is used.)
k Negligence of water draining will cause the cooling water remaining inside the engine to be frozen and
expanded to damage the engine parts.
Water draining procedure
1) Remove the radiator cap.
2) Loosen the water draining valve under the radiator to drain water from the inside.
3) Loosen the drain valve on the side surface of the cylinder to drain water from the inside.
4) After draining water, tighten the radiator cap and drain plug and valves.
(2) Remove the mud, dust and oil deposit and clean the outside.
(3) Perform the nearest periodic inspection before the storage.
(4) Drain or fill the fuel oil fully to prevent condensation in the fuel tank.
(5) Disconnect the battery cable from the battery negative (–) terminal.
(6) Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from depositing
or entrance.
(7) Select a well-ventilated location without moisture and dust for storage.
(8) Perform recharging once a month during storage to compensate for self-discharge.
4D94LE, 4D98E 3-13

3-10 Periodic maintenance schedule

The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities
of the fuel and lubricating oils used and handling status. General rules are described here.
Q: Test w: Replace
Maintenance period
Testing Every Every Every
Classification Item during Daily Every 250 Every 500
1000 2000 4000
operation hours or hours or
hours or hours or hours or
6 weeks 3 months
6 months one year two years
Checking and adding coolant Q
Testing coolant temperature
warning lamp Q
Cooling water Checking and cleaning radiator
system fins (*) Q
Adjusting cooling fan V-belt First testing at
tension 50 h Q
Draining coolant, cleaning cooling
system, adding new coolant w
Adjusting intake and exhaust
Cylinder head
valve clearances Q
Checking battery electrolyte
level and recharging Q
Electrical system
Testing battery warning lamp Q
Assurance of
Checking, cleaning, and testing
emission control
fuel injection valve (if necessary) Q
device
Checking engine oil level Q
Testing engine oil pressure
warning lamp Q
Engine oil
Replacing engine oil w
Replacing lubricating oil filter w
Acceleration Testing and adjusting governor
device relay and acceleration device Q
Checking fuel level and adding
fuel Q
Testing fuel filter warning lamp Q
Draining oil separator Q
Fuel
Testing oil separator Q
Cleaning oil separator (*) Q
Replacing fuel filter (*) w
Checking and replacing hoses,
Hose
fuel piping, and coolant piping Q Q
Intake and Cleaning and replacing air
exhaust systems cleaner element (*, **) Q w
*: If the engine is used in very dirty environment, check and clean every day.
**: If the engine is used in dirty or dusty environment, replace every 1000 h or as necessary.
3-14 4D94LE, 4D98E

4. ENGINE BODY
4. ENGINE BODY
4-1 Introduction ............................................................................................................................................. 4-2

4-2 Cylinder head.......................................................................................................................................... 4-3
4-3 Gear train and camshaft ....................................................................................................................... 4-12
4-4 Cylinder block ....................................................................................................................................... 4-18
4D94LE, 4D98E 4-1

4. ENGINE BODY
4-1 Introduction
Make preparation as follows before starting engine inspection and service:
(1) Fix the engine on a horizontal base.
k Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.
(2) Remove the cooling water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven
machine and engine, and drain cooling water, lubricating oil and fuel.
(3) Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so
as not to let any foreign matter enter the engine.
k Always wear glasses or other protectors when using compressed air or steam to prevent any foreign
matter from getting in the eyes.
a Any part which is found defective as a result of inspection or any part whose measured value does not
satisfy the standard or limit shall be replaced.
a Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state
of use should be replaced even when the measured value then satisfies the standard or limit.
4-2 4D94LE, 4D98E

4. ENGINE BODY
4-2 Cylinder head

(1) Components
(2) Disassembly procedure:

Disassemble in the order of the numbers shown in the illustration.
Remove the alternator assembly. (Point 1)
Remove the fan, pulley and V belt.
Remove the thermostat case. (Point 2)
Remove the fuel filter and fuel oil piping (Point 3)
Remove the oil level gauge assembly.
Remove the oil filter. (Point 4)
Remove the fuel injection pipes. (Point 5)
Remove the intake manifold assembly.
Remove the exhaust manifold assembly.
Remove the bonnet assembly.
Remove the rocker arm shaft assembly, push rods and valve caps. (Point 6)
Remove the cylinder head assembly and head gasket. (Point 7)
Remove the fuel injection nozzles and fuel return pipe. (Point 8)
Remove the intake/exhaust valves, valve stem seals and valve springs. (Point 9)
Remove the rocker arms from the rocker arm shaft.
4D94LE, 4D98E 4-3

4. ENGINE BODY
(3) Reassembly procedure: V-belt tension

Reverse order of the disassembly procedure.
98N {10kg}
(4) Servicing points
Point 1
Disassemble: A
• Loosen the mounting bolt while supporting
the alternator.
2
k Do not tilt the alternator toward the cylinder 1
block in a haste since it may damage the
alternator or pinch a finger.
3
Reassemble: YE0362-A
• The belt deflection (A) shall be 10 – 14 mm
(8 – 12 mm for a new belt).
Tension Adjustment
Reassemble:
• Replace the belt with a new one if cracked, 5
worn or damaged.
• Carefully prevent the belt from being
smeared with oil or grease. 4

2) Alternator
4) Adjuster
5) Bar (for adjusting 6
V-belt tension)
YE0363
6) Alternator
Point 2
Reassemble:
• Check the thermostat function. (See 3-6 in Chapter 3 for the check procedure.)
Point 3
Reassemble:
• Replace the fuel filter element with a new one.
Disassemble:
• Cover the fuel pipe opening with tape to prevent intrusion of foreign matters.
Point 4
Reassemble:
• Replace the oil filter with a new one.
• After fully tightening the filter manually, retighten it with a filter wrench (see 10-1-6 in Chapter 10) by 3/4
turn.
Point 5
Disassemble:
• Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of for-
eign matters.
4-4 4D94LE, 4D98E

4. ENGINE BODY
Point 6
Disassemble:
• Keep the removed push rods by attaching tags showing corresponding cylinder Nos.
Reassemble:
• Always apply oil to the contact portions of the push rods and clearance adjusting screws.
Point 7 Disassembly (Head bolt disassembly order)

Disassemble:
• Loosen the cylinder head bolts in two steps
in the illustrated order.
• Place the cylinder head assembly on a pa-
per board to prevent the combustion face
from any damage.
Reassemble:
• Remove the head gasket with a new one.
• Uniformly tighten the head bolts manually Assembly (Head bolt tightening order)
after applying oil on the threaded and seat
portions.
• They shall be tightened in two steps in the
reverse of the order for disassembly.
3
First step: 49 – 58.8 Nm {5 – 6 kgf•m}
Second step:
103.0 – 112.8 Nm {10.5 – 11.5 kgf•m}
Point 8
Disassemble:
• Carefully remove the fuel injection nozzle so as not to leave the tip end protector from being left inside
the cylinder.
Reassemble:
• Replace the fuel injection nozzle protector with a new one.
Point 9
Disassemble:
• When removing each intake/exhaust valve
from the cylinder head, use a valve spring
compressor (1) (see 10-1-4 in Chapter 10)
and compress the valve spring and remove
the valve cotter.
• Keep each removed intake/exhaust valve
after attaching a tag showing the corre-
sponding cylinder No.
• If cotter burr is seen at the shaft of each in-
take/exhaust valve stem, remove it with an
oilstone and extract the valve from the cylin-
der head.
Reassemble:
• Replace the valve stem seal with a new one when an intake/exhaust valve is disassembled.
• Carefully install each valve after oil application so as not to damage the valve stem seal.
• Different valve stem seals are provided for the intake and exhaust valves. Do not confuse them since
those for exhaust valves are marked with yellow paint.
• After assembling the intake/exhaust valve, valve stem seal, valve spring, seat, and cotter, tap the head
of the valve stem lightly for settling.
• Do not forget to install the valve cap.
4D94LE, 4D98E 4-5

4. ENGINE BODY
(5) Parts Inspection and measurement

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

Check mainly discoloration and crack. If Distortion at combustion surface
crack is suspected, perform color check.
(b) Combustion surface distortion

Apply a straight-edge (1) in two diago-
nal directions and on four sides of the
cylinder head, and measure distortion
with a thickness gauge (2).
(Unit: mm)
Standard Limit
Distortion 0.05 or less 0.15

Valve sink
(c) Valve sink

Using depth micrometer (3), measure
with the valve inserted to the cylinder
head.
(Unit: mm)
Standard Limit
Valve sink Intake 0.5 – 0.7 1.0

amount a Exhaust
0.6 – 0.8 1.1
Valve sink depth
(d) Seat width

Using valve caliper (4), measure the
seat width.
(Unit: mm) Valve seat width
Standard Limit
Intake 1.3 2.0

Width
Exhaust 2.2 3.0
4-6 4D94LE, 4D98E

4. ENGINE BODY
(e) Seat contact Valve seat contact

Apply a thin coat of minimum on valve
seat (1). Insert the valve in the cylinder
and push it against the seat to check
seat contact.
Continuous contact all

Standard
around
1
YE0395
(5-2) Valve guide Valve guide inside diameter

Mainly check damage and wear on the
i n s i d e w a l l . A p p l y s u p p l y pa r t c o d e
YM129150-11810 when replacing the part.
2 2 2
(a) Inside diameter
(Unit: mm)
Standard Limit
Valve stem
7.965 – 7.980 7.90
O.D.
Intake valve
YE0396
Valve guide
8.015 – 8.030 8.10
I.D.
Valve stem 2) Measuring positions
0.035 – 0.065 0.18
clearance
Valve stem
7.965 – 7.970 7.90
Exhaust valve
O.D.
Valve guide
8.015 – 8.030 8.10
I.D.
Valve stem
0.045 – 0.075 0.18
clearance
(5-3) Intake/exhaust valve Valve stem outside diameter

Mainly clean and check damage and wear
at the valve stem and seat.
(a) Seat contact: See 5-1-(e) above.
(b) Stem outside diameter: See 5-2-(a) 3
above.
YE0397
3) Measuring positions
4D94LE, 4D98E 4-7

4. ENGINE BODY
(c) Valve head thickness Valve head thickness

(Unit: mm)
Standard Limit
Intake 1.71 1.00
Exhaust 1.65 1.00

4
YE0398
(d) Valve stem bend Valve stem bend and length

Limit 0.01 mm
5
(e) Overall length

(Unit: mm)
6
Standard Limit
Intake 115 114.5
Exhaust 115 114.5 YE0399
4) Thickness 6) Stool
5) Length of valve
(5-4) Valve spring Valve spring

Mainly inspect damage and corrosion.
(Unit: mm) 1
Standard Limit
Free length 47.5 —
Inclination — 1.2
YE0400
Valve spring
YE0401
1) Free length of spring 2) Inclination of spring
4-8 4D94LE, 4D98E

4. ENGINE BODY
(5-5) Valve rocker arm Rocker arm hole diameter

Mainly inspect valve head cap contact sur-
face, inside surface defects and wear.
Slight surface defects shall be corrected
with an oilstone.
(Unit: mm)
Standard Limit
Arm hole diameter 18.50 – 18.52 18.57
Shaft O.D. 18.47 – 18.49 18.42

YE0402
Clearance 0.01 – 0.05 0.15
Rocker arm shaft outside diameter
(5-6) Valve rocker arm shaft

Mainly inspect seizure and wear at the sur-
face in sliding contact with the arm. The
rocker arm shaft diameter shall be as speci-
fied in (5-5) above.
YE0403
(5-7) Push rod Push rod bend

Mainly inspect the surface in contact with
the tappet and adjusting screw. Slight
defects shall be corrected with an oilstone.
Bend limit 0.03 mm or less
(5-8) Valve clearance adjusting screw 3

Mainly inspect the surface in contact with
the push rod.
Slight defects shall be corrected with an oil- YE0404
stone.
3) Thickness gauge
(5-9) Rocker arm spring
Mainly inspect surface defects and corro-
sion.
4D94LE, 4D98E 4-9

4. ENGINE BODY
(6) Valve seat correction

k Always check the oil clearance between the valve and valve guide before correcting the valve seat. If it
exceeds the limit, replace the valve or valve guide first to make the clearance satisfy the standard. Af-
ter correction, wash the valve and the cylinder head sufficiently with diesel oil to remove all grinding
powder or compound.
1. If the seat surface is slightly roughened: Seat cutter

perform [A] and [B] below.
1
2. If the seat is heavily roughened but the
width is almost normal, correct with a seat 2
grinder or seat cutter first. Then perform lap-
ping [A] and [B] below.
Intake Exhaust
Seat cutter angle
120° 90° 3
YE0405
1) Seat angle
2) Seat width
3) Cylinder head correction angle
3. If the seat is heavily roughened and the Seat grinder

width is much enlarged, grind the seat inner
surface with a seat grinder whose center an-
gle is 40°, then grind the seat outer surface 4
with a grinder whose center angle is 150° to
make the seat width match the standard.
Then perform seat correction as described
in 2), and then carry out lapping [A] and [B]
below.
Grinding wheel 1 2
5 YE0406
angle
40° 150°
4) Grinder
[A]: Lap the valve and seat with a mixture of 5) Grindstone
valve compound and engine oil.
[B]: Lap with engine oil only. Valve lapping
YE0407
4-10 4D94LE, 4D98E

4. ENGINE BODY
(7) Valve guide replacement Valve guide replacement

1. Use a valve guide extraction tool (10-1-1 in
Chapter 10) and extract the valve guide 2
from the cylinder head.
2. Put liquid nitrogen or ether (or alcohol) with 3
dry ice added in a container and put the
valve guide for replacement (code No. 1
YM129150-11810) in it for cooling. Then in-
sert it in with a valve guide inserting tool
(10-1-2 in Chapter 10).
3. Check the inside diameter and finish to the
4
standard inside diameter as required with a
reamer. YE0408
4. Check the projection from the cylinder head.

1) Cylinder head
Projection 14.7 – 15.0 mm 2) Valve guide extracting & inserting tool
3) Projection
4) Valve guide
k Do not touch the cooled valve guide with bare hands to avoid skin damage.
(8) Valve stem seal replacement

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

ter 10) for installation.
Measure the distance from the cylinder
head.
Projection 16.7 – 17.0 mm
5) Valve stem seal inserting tool

6) Valve stem seal
7) Valve guide
8) Cylinder head
4D94LE, 4D98E 4-11

4. ENGINE BODY
4-3 Gear train and camshaft

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

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

Reverse of the disassembly procedure.
4-12 4D94LE, 4D98E

4. ENGINE BODY
(4) Servicing points

Point 1
Disassemble:
• Remove the crankshaft pulley using a gear puller after removing the mounting bolt. When removing the
pulley with the gear puller, use a pad and carefully operate so as not to damage the thread. Set the
gear puller securely to prevent the pulley from being damaged.
Reassemble:
• When installing the crankshaft pulley, apply lube oil to the bolt and carefully assemble so as not to dam-
3 Bolt: 107.9 – 127.5 Nm {11.0 – 13.0 kgf•m}, apply lube oil.

age the oil seal.
Point 2
Reassemble:
• When installing the gear case cover, do not forget to install the two reinforcing bolts at the center.
• Measure the backlash of each gear.
Gear train
(Unit: mm)
Standard Limit
Crankshaft gear,
camshaft gear,
Fuel injection 0.08 – 0.14 0.16
pump gear, Idle
gear, PTO gear
Lubricating oil
0.09 – 0.15 0.17
pump gear
• Apply sealant and install the gear case cov-

er by correctly positioning the two dowel
pins.
1) Fuel injection pump drive gear 3) PTO gear 5) Lubricating oil pump gear
2) Camshaft gear 4) Crankshaft gear 6) Idle gear
Point 3
Disassemble:
1) Before loosening the mounting nuts of
the fuel injection pump, make marks (1)
on the rear part of the gear case
housing and fuel injection pump
mounting flange.
2) Using a wrench, hold the bolt of the
crankshaft pulley so that the engine will
not move and remove mounting nut (2)
and lock washer (3) of the pump drive
gear.
(1)
0000593
0000593A
4D94LE, 4D98E 4-13

4. ENGINE BODY
3) Using the gear puller having two bolts,

remove fuel injection pump drive gear
(4) from the fuel injection pump shaft.
a The fuel injection pump shaft has a
tapered portion with a woodruff
key.
A certain pressure is applied by the
puller. You can remove the gear
from the shaft easily by lightly
hitting the bolt at the center of the
gear with a hammer.
4) Remove the three nuts that are fixing
the fuel injection pump to the rear of the
gear case.
5) Remove the fuel injection pump.
(4)
Reassemble:
(3)
1) Using the three nuts, fix the mounting
flange of the fuel injection pump to the (2)
rear of the gear case housing. Align
match marks (1) at the rear of the gear 0001698A-A
case housing and mounting flange of

the fuel injection pump. 4
2) While aligning match marks (B) at fuel
injection pump drive gear (4) and idler
gear (5), install fuel injection pump drive
gear (4) to the fuel injection pump shaft.
3) Install drive gear mounting nut (2) and
washer (3). Using the wrench, hold the
engine at the crankshaft pulley and 5
tighten the mounting nut to the torque of
49 – 53 Nm {5 – 5.4 kgf•m}.
YE1002
Point 4
Reassemble:
• Assemble crankshaft gear A, fuel injection pump drive gear B and camshaft gear C at the same time by align-
ing with idle gear A, B and C marks.
• Install the idle gear shaft with the oil hole facing upward.
Point 5
Reassemble:
• Install the PTO gear with its inner spline side facing the flywheel.
4-14 4D94LE, 4D98E

4. ENGINE BODY
Point 6
Disassemble:
• Install a bolt as a handle in the hole at the
end face of the flywheel and remove careful-
ly so as not to damage the ring gear.
• 3 Flywheel mounting bolt: 186.3 –

Reassemble:
205.9 Nm {19 – 21 kgf•m}, apply lube oil
Point 7 Camshaft end play

Disassemble: 1
• Measure the camshaft end play.
2
(Unit: mm)
Standard Limit
End play 0.05 – 0.20 0.30
• If the measured end play exceeds the limit,

replace the thrust metal.
Disassemble:
• Since the camshaft gear is shrink-fit, heat it 3
to 180 – 200°C for extraction. YE0412
• For camshaft removal, raise the engine with
its mounting flange at the bottom. After re- 1) Camshaft gear
moving the thrust metal mounting bolt from 2) Thrust metal
the camshaft gear hole, extract the cam- 3) End play
shaft carefully so as not to damage the
bearing bushing.
• Rotate the camshaft a few turns before ex-
tracting it to prevent the tappet from being
caught by the cam.
• After removing the camshaft, set the engine
horizontal and fix it on the base.
k Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to
the horizontal position. Proceed carefully so as not to lose balance.
Point 8
Reassemble:
• Do not forget to install the oil pan mounting bolts on the bottom side when installing the gear case.
• Apply sealant (code No.YM977770-1207F) and install the gear case by matching the two dowel pins.
Point 9
Reassemble:
• Replace the oil seal whenever disassembled.
• Apply lithium grease at the time of assembly.
4D94LE, 4D98E 4-15

4. ENGINE BODY
(5) Parts inspection and measurement

(5-1) Camshaft
Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and
gear damage.
Camshaft bend
1. Camshaft bend measurement
Support the camshaft with V-blocks. Rotate 1
the camshaft and measure the runout at the
center of the camshaft and at each journal
with a dial gauge. Half of the runout is the
bend.
(Unit: mm)
Standard Limit
2
Bend 0 – 0.02 0.05
YE0413
2. Intake/exhaust cam height measurement 1) Dial gauge

(Unit: mm) 2) V-block
Standard Limit
Cam height
Cam height 42.435 – 42.565 42.185
3. Camshaft outside diameter and bearing

hole diameter measurement 3 4
Measure the camshaft outside diameter with
a micrometer. The oil clearance shall be
calculated by subtracting the measured
camshaft outside diameter from the camshaft
bushing inside diameter after insertion to the
cylinder measured with a cylinder gauge. YE0414
(Unit: mm)
3) Cam height
Standard Limit
4) Micrometer
Camshaft O.D. 49.925 – 49.950 49.890
Gear side
Bushing I.D. 49.990 – 50.055 50.130 Camshaft outside diameter
Oil clearance 0.040 – 0.130 0.240

Intermediate
Camshaft O.D. 49.910 – 49.935 49.875 5

position
6
Block I.D. 50.000 – 50.025 50.100
Oil clearance 0.065 – 0.115 0.225
Camshaft O.D. 49.925 – 49.950 49.890

Flywheel
side
Block I.D. 50.000 – 50.025 50.100

YE0415
Oil clearance 0.050 – 0.100 0.210
5) Flywheel side
6) Micrometer
4-16 4D94LE, 4D98E

4. ENGINE BODY
(5-2) Idle gear Idle gear

Mainly check the bushing seizure and wear,
and gear damage.
1. Idle gear shaft outside diameter and bush- 7 10
ing inside diameter measurement
(Unit: mm)
Standard Limit 8 9
Idle gear shaft

45.950 – 49.975 45.900
outside diameter
Bushing inside
46.000 – 46.025 46.075
diameter YE0416
Clearance 0.025 – 0.075 0.175

7) Idle gear shaft 9) Inside diameter of gear
8) Shaft diameter 10) Idle gear
(5-3) PTO gear

Mainly check sticking of bearings on both
sides, gear damage and looseness, and
gear shaft damage and wear.
(6) Oil seal replacement

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

Replace the bushing using the special service tool (see 10-1-7 in Chapter 10).
4D94LE, 4D98E 4-17

4. ENGINE BODY
4-4 Cylinder block

(1) Components
1) Oil filter

Disassemble in the order of the numbers in the illustration.
Perform steps to in the cylinder head disassembly procedure.
Perform steps to in the gear train disassembly procedure.
Remove the oil pan. (Point 1)
Remove the lubricating oil suction pipe.
Remove the piston w/rod. (Point 2)
Remove the flywheel housing. (Point 3)
Remove the bearing metal caps. (Point 4)
Remove the crankshaft. (Point 5)
Remove the tappets.
Remove the piston and piston rings. (Point 6)
Remove the oil seal from the flywheel housing. (Point 7)
4-18 4D94LE, 4D98E

4. ENGINE BODY
(3) Reassembly procedure:

Reverse of the disassembly procedure.
(4) Servicing points Connecting rod side cap

Point 1
Disassemble:
• Sealant is applied to the oil pan mounting sur-
face on the cylinder block. Carefully operate
so as not to damage or distort the bonding
surface.
Reassemble:
• Apply sealant (code No. YM977770-1207F)
before reassembly.
Point 2 1
Disassemble:
• Measure the connecting rod end play. 2
Standard 0.13 – 0.23 mm
• Carefully remove the carbon deposit on top YE0418

of the cylinder block so as not to damage
the inner side of the cylinder block. 1) Crankshaft
• Set the piston at the B.D.C. position and re- 2) Thickness gauge
move the connecting rod cap. Then set the
piston at the T.D.C. position, and push the
connecting rod big end with the wooden
shaft of a hammer. Proceed carefully so as
not to cause the cylinder block catch the rod
big end. Set the connecting rod caps and
crankpin metals in their correct combina-
tions.
Reassemble:
• Apply oil especially carefully to the sliding contact surfaces of the pistons, rods and rings.
• Use the piston insertion tool (See 10-1-9 in Chapter 10) to insert each piston w/rod in the cylinder block
3 Connecting rod metal cap mounting bolt: 53.9 – 58.8 Nm {5.5 – 6.0 kgf•m}, apply lube oil
and install the bearing metal cap.
Point 3
Disassemble:
• Place the engine on a stable base with the cylinder block upper surface facing down, and remove the
flywheel housing carefully so as not to damage the combustion surface.
Reassemble:
• Apply sealant (code No. YM977770-1207F) and install the flywheel housing by matching the two dowel
pins. After assembly, raise the engine with its mounting flange on the bottom side.
k Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Carefully
operate so as not to lose balance.
4D94LE, 4D98E 4-19

4. ENGINE BODY
Point 4 Crankshaft end play

Disassemble: <Measuring method 1>
• Before removing the main journal bearing,
measure the crankshaft end play.
(Unit: mm)
Standard Limit
End Play 0.11 – 0.21 0.28
Reassemble:
• If the end play exceeds the standard, re-
place
the thrust metal with an oversize one. YE0419
0.25 mm OS YM129900-02361 (Upper) <Measuring method 2>

Code No. YM129900-02371 (Lower) (1)
Standard
2.055 – 2.105 mm
thickness
(2)
Disassemble: (7)
(3)
• Remove the main metal caps, cap side
bearings, and thrust metals. Place each
(6) (4)
thrust metal with identification of the position
and direction.
Reassemble:
• Carefully install each thrust metal so that the (5)
grooved one is positioned away from the
cap.
• Do not confuse the upper and lower main 0001717-A
bearing metals. The upper main bearing
metal (cylinder block side) has an oil hole, 1) Cylinder block 5) Shim gauge
and the lower one does not. The "wheel and 2) Crankshaft 6) Thrust
arrow" marks on the cap shall face the fly- 3) Thrust metal 7) Standard width
wheel.
4) Main metal cap
3 Main metal cap mounting bolt: Main bearing
107.9 – 117.7 Nm {11.0 – 12.0 kgf•m}
apply lubrication oil 2
1 3
Point 5
Disassemble: 4
• Remove the crankshaft. Remove each main
bearing metal upper (cylinder block side)
and pair it with the main metal cap side low-
er metal.
k Carefully prevent damage to the bearing or 5

finger injury when removing the crankshaft
because it is heavy.
YE0420
1) Flywheel side 4) Cap side main

2) Thrust metals bearing metals
3) Cylinder block side 5) Timing gear side
main bearing metals
4-20 4D94LE, 4D98E

4. ENGINE BODY
Point 6 Piston ring

Disassemble:
• Use the piston ring replacer (See 10-1-10 in
Chapter 10), remove the piston rings.
• Remove the circlip and remove the piston
pin by pushing it out.
Reassemble:
• Install each piston ring on the piston, with
the punched manufacturer’s mark facing up- 1
ward.
YE0421
1) Punched manufacturer’s
mark (make it face upward.)
Reassemble: Ring joints

• The piston ring joints shall be staggered at
2
by 120° intervals. Do not position the top
ring joint vertical to the piston pin. The coil
expander joint shall be opposite to the oil
ring joint. 5
2) Oil ring joint 3

3) Top ring joint
4) Expander joint
5) Second ring joint
YE0422
Reassemble: Assembly direction of connecting rod and piston

• When installing the piston pin to the con- 7
necting rod and piston, the punched match
mark on the big end of the connecting rod
shall be opposite to the size mark on the
6 8
piston top.
Reassemble:
• Install the piston in the cylinder block with 9
10
the punched mark on the big end of the con-
necting rod on the nozzle side. (The em-
bossed mark at the connecting rod I-beam 11
section shall be on the flywheel side.)
6) Camshaft side
12
7) Piston ID mark
8) Fuel injection nozzle side
9) Cylinder block size mark 13
10) Flywheel side
11) Piston ID mark
12) Embossed mark
(flywheel side) YE0423
13) Match mark
4D94LE, 4D98E 4-21

4. ENGINE BODY
Point 7
Reassemble:
• Replace the oil seal with a new one whenever disassembled. Apply lithium grease at the time of assem-
bly.
(5) Parts inspection and measurement

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

Check if there is any discoloration or crack.
If crack is suspected, perform color check.
Sufficiently clean the oil holes and check
they are not clogged.
2. Cylinder bore and distortion
Measure at 20 mm below the crest of the
liner, at 20 mm from the bottom end and at
the center.
Roundness: Maximum value of the differ-
ence between the measured
values in the same cross sec-
tion.
Cylindricity: Maximum value of the differ-
ence between the measured Cylinder bore measurement positions
values in the same direction.
(Unit: mm)
a 20 mm
Standard Limit
d
4D94LE 94.000 – 94.030 94.130 e
Bore b
4D98E 98.000 – 98.030 98.130
Roundness 0.01 or less 0.03

c
Cylindricity 0.01 or less 0.03 20 mm
0000230B-1
Measure in two directions d and e at points a, b and c.
3. If the limit is exceeded or any surface defect

is found, repair by boring and honing. Use
an oversized piston (and new piston rings)
as required.
Piston assembly code

Standard size of outer Piston ring assembly Boring dimension
0.25 mm OS (incl./Piston ring
diameter (mm) code (mm)
assembly)
4D94LE YM129931-22900 f94.190 – f94.205 YM129901-22950 f94.250 – f94.280
4D98E YM129903-22940 f98.185 – f98.200 YM129903-22950 f98.250 – f98.280
4-22 4D94LE, 4D98E

4. ENGINE BODY
(5-2) Crankshaft Inspection by color check

Mainly check seizure and wear of the crank-
pins and main journals. Since the crankshaft
gear is shrink-fitted, heat to 180 to 200°C
when extraction is necessary.
1. Shaft portion color check
After washing the crankshaft, inspect it by
means of color check or a magnaflux
inspector. Replace it if cracked or heavily
damaged. Slight defects shall be corrected
by grinding.
2. Crankshaft bend
Support the crankshaft journals at both ends
with V-blocks. Use a dial gauge and mea-
YE0426
sure the runout at the center journal while
rotating the shaft to inspect the bend.
Crankshaft bend measurement
Limit 0.02 mm or less

1
2
3
4 5
YE0427
1) Bend
2) Deflection
3) Dial gauge
4) V-block
5) V-block
4D94LE, 4D98E 4-23

4. ENGINE BODY
3. Crankpin and main journal measurement Measuring position of the crankpin

Measure the outside diameter, roundness and crank journal
and taper at each crankpin and main journal.
Correct by grinding if unevenly wear, round-
ness exceeding the limit or insufficient out-
side diameter is found. Replace if the defect
is excessive.
• Crankpin (Unit: mm)

Standard Limit
Crankpin outside
57.952 – 57.962 57.902
diameter
Connecting rod
1.492 – 1.500 —
metal thickness
Connecting rod hole
58.000 – 58.026 —
diameter
Oil clearance 0.038 – 0.074 0.150
If the clearance limit is exceeded, use an

undersized bearing.
0.25 mm US bearing
YM129900-23351
Part code
Standard thickness 1.617 – 1.625 mm 6
Crankpin machining 7
f57.702 – f57.712 mm YE0428
dimension
6) Crankshaft journal 7) Crankpin
• Crank journal (Unit: mm)
Standard Limit
Journal O.D. 64.952 – 64.962 64.902

Main metal
1.995 – 2.010 —
thickness
Main metal hole
65.000 – 65.020 —
diameter
Oil clearance 0.038 – 0.068 0.150
If the clearance limit is exceeded, use an

undersized bearing.
0.25 mm US YM129900-02320 (Upper)
Crank journal bearing
Part code YM129900-02330 (Lower)
Standard thickness 2.125 – 2.130 mm

Main journal bearing
f64.702 – f64.712 mm
machining dimension
k If the oil clearance is excessive though the thicknesses of the main journal and crankpin metals are
normal or if partial uneven wear is observed, re-grind the crankshaft and use an oversized metals.
k If rust of surface roughening exists on the rear side of the metals, coat it with blue or minimum. Then
assemble the crankpin metal to the connecting rod, and tighten the rod bolt to the specified torque to
check the metal for contact. If the contact surface occupies 75% or more, the metal is normal. If the
contact surface is insufficient, the metal interference is insufficient. Replace the metal with a new one.
4-24 4D94LE, 4D98E

4. ENGINE BODY
(5-3) Thrust metal inspection

Inspect any damage or wear.
1. Thrust metal thickness (Unit: mm)
Standard Limit
Thickness 1.930 – 1.980 1.850
If the side gap is exceeded, use an over-

sized thrust metal.
0.25 mm OS YM129900-02370 (Upper)

Code No. YM129900-02360 (Lower)
Standard
2.055 – 2.105 mm
thickness
(5-4) Piston Piston outside diameter

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

Measure the long diameter at 22 mm from 1
the bottom end of the piston of the oval hole 22mm
in the vertical direction to the piston pin hole. YE0429
(Unit: mm)
Piston pin outside diameter
Standard Limit
4D94LE 93.945 – 93.955 93.900

Long
diameter
4D98E 97.940 – 97.950 97.900
Clearance Min. — 0.050

between piston
and cylinder Max. — 0.080
If the clearance between piston and cylinder

exceeds the limit, use an oversized piston. YE0430
Measure at positions a, b and c in directions A and B.
0.25 mm OS Standard dimension of outer

Boring dimension (mm)
Piston assembly code diameter (mm)
4D94LE YM129931-22900 f94.190 – f94.205 f94.250 – f94.280
4D98E YM129903-22940 f98.185 – f98.200 f98.250 – f98.280
4D94LE, 4D98E 4-25

4. ENGINE BODY
2. Piston pin hole measurement Piston pin hole

(Unit: mm)
Standard Limit
Piston pin hole
30.000 – 30.009 30.039
diameter
Piston pin outside
29.989 – 30.000 29.959
diameter
Oil clearance 0.000 – 0.020 0.080
YE0431
Measure at positions a and b in directions A and B.
3. Piston ring, ring groove and piston ring end Piston ring components
clearance measurement
• Except for the top ring, to measure the 1
piston ring groove width, first measure
the width of the piston ring. Then insert
the piston ring into the ring groove. In- 2
sert a thickness gauge in between the
piston ring and groove to measure the
gap between them. Obtain the ring 3
groove width by adding ring width to the
measured side clearance.
1) Top ring
YE0432
2) Second ring
3) Oil ring Measuring side clearance
4) Width
5) Thickness
5
YE0433
4-26 4D94LE, 4D98E

4. ENGINE BODY
• To measure the piston ring end clear- Ring joint end clearance measurement
ance, push the piston ring into the
sleeve using the piston head, insert a 6
thickness gauge in end clearance to
measure. The ring shall be pushed in to
7
approx. 30 mm above the bottom end of
the cylinder. For the top ring, measure
only the piston ring joint end clearance
in normal state.
(Unit: mm) 10 8
Standard Limit 9 YE0434
Piston ring groove
2.040 – 2.060 — 6) Cylinder block head surface
width
Piston ring width 1.940 – 1.960 1.920 7) Joint end clearance
Top ring
8) Approx. 30 mm from bottom end of cylinder

Piston side
0.080 – 0.120 — 9) Piston ring
clearance
Piston end 10) Cylinder block
0.250 – 0.450 0.540
clearance
Piston ring groove
2.080 – 2.095 2.195
width
Second ring
Piston ring width 1.970 – 1.990 1.950

Piston side
0.090 – 0.125 0.245
clearance
Piston end
0.450 – 0.650 0.730
clearance
Piston ring groove
3.015 – 3.030 3.130
width
Piston ring width 2.970 – 2.990 2.950
Oil ring
Piston side
0.025 – 0.060 0.180
clearance
Piston end
0.250 – 0.450 0.550
clearance
4D94LE, 4D98E 4-27

4. ENGINE BODY
4. Oversize piston, piston ring and applicable head gasket

1. 4D94LE
Item Standard 0.25 OS 0.50 OS 1.00 OS
Piston assembly YM129931-22100 YM129931-22900 YM129931-22920 YM129931-22940
Piston YM129931-22010 YM129931-22700 YM129931-22720 YM129931-22740
Ring assembly YM129901-22050 YM129901-22950 YM129901-22970 YM129901-22990
1st ring YM129901-22100 YM129901-22750 YM129901-22850 YM129901-22650
2nd ring YM129900-22110 YM129900-22760 YM129900-22860 YM129900-22660
Oil ring YM129900-22160 YM129900-22770 YM129900-22870 YM129900-22670

Applicable head YM129901-01350 YM129901-01350 YM129901-01350 YM129901-01370
gasket
2. 4D98E
Item Standard 0.25 OS 0.50 OS 1.00 OS
Piston assembly YM129903-22120 YM129903-22940
Piston YM129903-22020 YM129903-22700
Ring assembly YM129903-22050 YM129903-22950
1st ring YM129903-22100 YM129903-22750 None None
2nd ring YM129902-22110 YM129902-22760
Oil ring YM129902-22160 YM129902-22770

Applicable head YM729903-01350 YM129903-01350
gasket
4-28 4D94LE, 4D98E

4. ENGINE BODY
(5-5) Connecting rod Twist and parallelism measurement

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

Use a connecting rod aligner and measure 2
3
the twist and bend.
(Unit: mm)
Standard Limit
dimension dimension YE0435
Twist and 0.03 or less Twist measurement using

0.08
parallelism per 100 a connecting rod aligner
3. Connecting rod small end measurement

Measure the piston pin outside diameter
according to (5-4) -1 described above.
4
(Unit: mm)
Standard Limit
Piston pin I.D.
bushing 30.025 – 30.038 30.068
Piston pin O.D. 29.987 – 30.000 29.959
Oil clearance 0.025 – 0.051 0.109 YE0436
If the bushing is to be replaced because the Connecting rod small end

oil clearance exceeds the limit, use spare
part code No. YM129900-23911.
4. Connecting rod big end measurement

Measure the crankpin and metal according
to (5-2) -3 described above.
YE0437
1) Parallelism 4) Connecting rod aligner

2) Twist 5) Cylinder gauge
3) Mandrel
4D94LE, 4D98E 4-29

4. ENGINE BODY
(5-6) Tappet Tappet

Mainly check the tappet contact surface with
the cam and push rod. Slight surface
defects shall be corrected with an oilstone.
1. Tappet stem outside diameter measurement

(Unit: mm)
Standard Limit
Tappet stem
11.975 – 11.990 11.955
O.D.
Tappet hole I.D. 12.000 – 12.018 12.038
1 2 YE0438
Oil clearance 0.010 – 0.043 0.083
1) Abnormal contact surface

2) Normal contact surface
Tappet stem outside diameter measurement
YE0439
(6) Cylinder bore correction Items to be prepared for honing

1. Slight uneven worn, flawed, etc. shall be
corrected by honing only. If the cylinder is
unevenly worn partially, flawed or otherwise
damaged and cannot be repaired simply by
honing, rebore the cylinder first and then
hone. See (5) (5-1)-3 for the boring
dimension. 4
2. Items to be prepared for honing
• Flex-Hone (see 10-1-8 in Chapter 10) 6 7
• Electric drill 50% 50%
• Honing fluid (50:50 mixture of lube oil
and diesel oil)
3
5 YE0440
3) Flex-hone
4) Electric drill
5) Honing fluid
6) Lube oil
7) Diesel oil
4-30 4D94LE, 4D98E

4. ENGINE BODY
3. Apply the honing fluid to the Flex-Hone and Honing cross hatch
turn the electric drill at 300 to 1,200 rpm.
Then insert the Flex-Hone into the cylinder
bore while turning it, and move it up and
down for about 30 sec. to obtain a honing
mark with a cross hatch angle of 30 to 40°.
YE0441
k Avoid faster revolution than 1,200 rpm since it may cause breakdown.
k Do not insert or extract the Flex-Hone in stopped state because the cylinder will be damaged.
k Limit the honing depth to 1/1,000 mm each time.
• Cylinder overhaul (reference)
Service life of cylinder block (H3)

(H3 = 3H1)
Boring and honing interval (H2)

(H2 = 1.5H1)
Time for honing (H1)
Increase in
Increase in lubricating Increase in lubricating Increase in lubricating lubricating
oil consumption oil consumption oil consumption oil consumption
or blow-by or blow-by or blow-by or blow-by
Honing Boring Honing
(Study if an oversized piston or piston ring is usable.)

YE0568
(7) Piston pin bushing replacement

Replace bushing by using the special service tool (see 10-1-3 in Chapter 10).
(8) Oil seal replacement

1. Replace oil seal, when flywheel housing is removed. Extract the used oil seal.
2. Insert a new oil seal with the oil seal insertion tool.
3. Apply lithium grease.
4D94LE, 4D98E 4-31

5. LUBRICATION SYSTEM
5-1 Lubrication system diagram .................................................................................................................... 5-2

5-2 Trochoid pump components ................................................................................................................... 5-2
5-3 Disassembly (reverse the procedure below for assembly) ..................................................................... 5-3
5-4 Servicing points ...................................................................................................................................... 5-3
5-5 Parts inspection and measurement ........................................................................................................ 5-4
4D94LE, 4D98E 5-1

5-1 Lubrication system diagram
1) Crankshaft bearing 5) Oil pan

2) Camshaft bearing 6) Lube oil pump
3) To cylinder head (with built-in pressure regulator valve)
(valve rocker arm lubrication) 7) Fuel injection pump
4) To gear case 8) Lube oil filter
(oil pump gear lubrication)
5-2 Trochoid pump components
1) Outer rotor 2
2) Gear case
3) Crankshaft
4) Punch mark 1
4
3
YE0444
5-2 4D94LE, 4D98E

5-3 Disassembly (reverse the procedure below for assembly)

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

Point 1
Disassemble:
• Check if the oil pump rotates smoothly and see that there is no play between the shaft and gear, and
inner rotor.
Reassemble:
• Install the outer rotor in the gear case so that the punch mark on the end face is seen.
• When replacing the lubricating oil pump, replace the whole ass’y.
Point 2
Disassemble-Reassemble:
• Only wash the pressure regulator valve. Disassembly is unnecessary unless any abnormality in opera-
tion is detected.
4D94LE, 4D98E 5-3

5-5 Parts inspection and measurement

(1) Outer rotor Oil clearance
(Unit: mm) 2
Standard Limit 1
Oil clearance 0.100 – 0.155 0.25
Side clearance 0.05 – 0.10 0.15

Tip clearance — 0.16
(2) Rotor shaft YE0445
(Unit: mm)
1) Gear case
Standard Limit 2) Outer rotor
Shaft O.D. 12.925 – 12.970 12.915
Side clearance
Bearing I.D. 12.980 – 13.020 13.050
3
Clearance 0.010 – 0.065 0.105
0001615A-A
3) Depth micrometer
Lube oil pump bearing

4
5 6
7
0000047A-A
4) Rotor shaft
5) Shaft O.D.
6) Bearing I.D.
7) Gear case
5-4 4D94LE, 4D98E

6. COOLING SYSTEM
6. COOLING SYSTEM
6-1 Cooling water system ............................................................................................................................. 6-2

6-2 Cooling water pump components ........................................................................................................... 6-3
6-3 Disassembly (reverse the procedure below for assembly) ..................................................................... 6-3
6-4 Servicing points ...................................................................................................................................... 6-3
4D94LE, 4D98E 6-1

6. COOLING SYSTEM
6-1 Cooling water system
1) From cylinder head

3) Radiator
4) Bypass
6-2 4D94LE, 4D98E

6. COOLING SYSTEM
6-2 Cooling water pump components
6-3 Disassembly (reverse the procedure below for assembly)

Remove the alternator. See 4-2 (2) - in Chapter 4.
Remove the fan, fan V-belt and fan pulley. See 4-2 (2) - in Chapter 4.
Remove the thermostat cover. See 4-2 (2) - in Chapter 4.
Remove the cooling water pump. (Point 1)
Remove the thermostat. (Point 2)
6-4 Servicing points

Point 1
Disassemble-Reassemble:
• Check to see that the cooling water pump bearing is free from abnormal noise, sticking or play and wa-
ter leakage from the bearing. If replacement is necessary, replace the whole cooling water pump ass’y.
Point 2
Disassemble:
• Check the thermostat function. See 3-6 (1) in Chapter 3 for the inspection method.
4D94LE, 4D98E 6-3

7. FUEL INJECTION PUMP, GOVERNOR
7-1 Specifications.......................................................................................................................................... 7-2

7-2 Component parts .................................................................................................................................... 7-3
7-3 Fuel injection pump system diagram ...................................................................................................... 7-4
7-4 Removal and installation of fuel injection pump...................................................................................... 7-5
7-5 Fuel system ............................................................................................................................................ 7-6
7-6 Structure and operation of pump ............................................................................................................ 7-8
7-7 Operation of plunger ............................................................................................................................. 7-12
7-8 All speed governor ................................................................................................................................ 7-18
7-9 Structure and operation of timer ........................................................................................................... 7-26
7-10 Magnet valve ........................................................................................................................................ 7-28
7-11 Improvement of startability at very low temperature (4D94LE)............................................................. 7-29
7-12 Cold spark device (CSD) (4D98E) ........................................................................................................ 7-30
4D94LE, 4D98E 7-1

7-1 Specifications
Type — VM
Number of injection cylinders — 4
Turning direction
— Right
(Seen from gear side)
Max. revolving speed (Pump) rpm 2,490
Plunger diameter mm 12
Advance angle of 4D94LE deg./rpm 3.5 / 800 – 1,350

speed timer 4D98E deg./rpm 5 / 500 – 1,350
Revolving speed control — All-speed governor
Fluctuation (750 rpm) % 4
Weight kg Approx. 5.5
Lubrication method — Lubrication with fuel oil
Max. pressure in pipe MPa {kgf/cm2} Approx. 53.9 {550}
Safety device against reverse revolution — Installed
7-2 4D94LE, 4D98E

7-2 Component parts
1) Drive shaft 8) Plunger

2) Control lever 9) Delivery valve
3) Flyweight 10) Plunger spring
4) Governor lever 11) Timer
5) Full-load adjustment screw 12) Cam disc
6) Magnet valve 13) Roller holder
7) Distributor head 14) Feed pump
4D94LE, 4D98E 7-3

7-3 Fuel injection pump system diagram
1) Fuel injection valve

2) Fuel tank
3) Fuel injection pump
4) Fuel filter and water separator with priming pump
7-4 4D94LE, 4D98E

7-4 Removal and installation of fuel injection pump

(1) Disassembly procedure: Perform the steps according to the indicated numbers.
1) Perform 4-2 (2), steps and in chapter 4 of the disassembly procedure for the cylinder head.
2) Perform 4-3 (2), steps and in chapter 4 of the disassembly procedure for the gear train and
camshaft. (Point 1)
(2) Assembly procedure: Carry out assembly in

the reverse order to disassembly.
(3) Point of work

Point 1: Fuel injection pump drive gear
Removal • Make engagement marks B
on the fuel injection pump
drive gear and the idle gear
with a marker, and then re-
m ove th e fuel i nje cti on
pump drive gear.
Installation • When assembling, match
marks B of the gears.
3 Gear mounting nut:
49 – 53 Nm {5 – 5.4 kgf•m}
(4) Testing and measuring parts

Ask the service network of the pump manufacturer to test and measure the parts and adjust the setting of
them.
4D94LE, 4D98E 7-5

7-5 Fuel system
1) Fuel tank 6) Regulating valve 11) Overflow valve

2) Sedimenter 7) Feed pump 12) Overflow pipe
3) Priming pump 8) Plunger 13) Nozzle
4) Fuel filter 9) Plunger barrel
5) Drive shaft 10) Magnet valve
7-6 4D94LE, 4D98E

(1) Outline
• The fuel oil in the fuel tank (1) is sucked by
the feed pump (7) in the injection pump
through the sedimenter (2) and fuel filter (4)
to the fuel inlet of the injection pump.
• The fuel filter (4) filtrates the fuel oil. It may
have a sedimenter (2) to separate water in
its bottom.
• The fuel oil sucked to the fuel inlet is pres-
surized by the feed pump (7) and supplied
into the pump chamber.
• The pressure of the fuel oil in the pump
chamber is in proportion to the pump speed.
If it exceeds a certain level, however, the ex-
cessive oil is returned to the suction side by
the regulating valve (6).
• The fuel oil in the pump chamber is sent
through the fuel oil passage in the distributor
head to the plunger (8). Then, the fuel oil is
pressurized high by the plunger (8) and sent
through the injection pipe to the nozzle (13)
and nozzle holder.
• The overflow valve (11) on the injection
pump keeps the oil temperature in the pump
chamber constant and returns excessive
fuel oil to the fuel tank (1).
4D94LE, 4D98E 7-7

7-6 Structure and operation of pump
1) Drive shaft 11) Magnet valve

2) Regulating valve 12) Plunger
3) Control lever shaft 13) Outlet port
4) Control lever 14) Delivery valve
5) Flyweight 15) Control sleeve
6) Governor spring 16) Plunger spring
7) Idle spring 17) Cam disc
8) Full-load adjustment screw 18) Cross coupling
9) Tension lever 19) Drive gear
10) Governor lever assembly 20) Feed pump
7-8 4D94LE, 4D98E

(1) Outline
1) Pump
• Drive shaft (1) receives the engine pow-
er directly through the timing belt (or
gear) and transmits it to cam disc (3)
through cross coupling (2).
• Since the positioning pin fitted to cam
disc (3) is fitted to the groove of the
plunger flange, plunger (4) revolves
similarly to cam disc (3).
• Cam disc (3) has a face cam and recip-
rocates by the specified cam lift on roller
(5) of the roller holder assembly.
• There are 2 plunger springs having set
forces on the outside of plunger (4),
which return down the plunger pushed
up by cam disc (3).
• In this way, the plunger is rotated by
drive shaft (1) and reciprocated by cam
disc (3).
• When the fuel oil pressurized high by
the plunger flows into outlet port (6), de-
livery valve (7) opens and the fuel oil is
injected through the nozzle and nozzle
holder into the combustion chamber of
the engine.
4D94LE, 4D98E 7-9

2) Governor
• The governor is installed above the
pump chamber and consists of flyweight
holder (1), governor lever assembly (2),
etc.
• Flyweight holder (1) holds 4 flyweights
(3) and governor sleeve (4) and is sup-
ported by the governor shaft. Drive
gear (5) is engaged with flyweight hold-
er gear (6) to increase the speed of
drive shaft (7) and rotate flyweight hold-
er assembly (1).
• Governor lever assembly (2) is support-
ed by the pivot bolt of the pump hous-
ing. Ball pin (8) at the lower part of the
governor lever assembly is inserted in
control sleeve (9) which rocks the out-
side of plunger (15).
• Governor spring (10) at the upper part is
connected to tension lever (12) by re-
taining pin (11) and its end is connected
to control lever (14) through control le-
ver shaft (13).
• Control lever (14) is connected to the
accelerator pedal through the link. It
changes the set force of governor
spring (10) according to the leaning an-
gle.
• The difference between the set force of
governor spring (10) and the centrifugal
force of flyweight (3) corresponds to the
moving distance of control sleeve (9), or
the injection rate.
3) Timer
• The timer is installed in the bottom of
the injection pump. Timer spring (2)
having a set force is installed to low-
pressure side A of timer piston (1).
• On the opposite side (high-pressure
side B), the fuel oil pressure in the
pump chamber is applied directly. Tim-
er piston (1) moves to rotate roller hold-
er (4) through roller holder pin (3),
according to the balance between the
fuel oil pressure and timer spring (2).
• When the piston moves to compress
timer spring (2), the injection timing is
advanced (roller holder (4) moves in the
reverse direction).
• In this way, the timer controls the injec-
tion timing according to the fuel oil pres-
sure in the pump chamber.
7-10 4D94LE, 4D98E

(2) Feed pump (Vane type)

• The feed pump sucks up fuel oil A from
the tank and sends it into the pump
chamber.
• The feed pump consists of rotor (1),
blades (2) (vanes), and liner (3). Rotor
(1) is driven with drive shaft (4). Liner
(3) is eccentric to rotor (1), and there
are 4 blades (2) (vanes) between the ro-
tor and liner.
• If rotor (1) starts revolution, blades (2)
are pressed against the inside wall of
liner (3) by the centrifugal force. As ro-
tor revolves, the volume of each cham-
ber changes.
• When the volume of each chamber is in-
creased, fuel oil A is sucked up from the
fuel tank. When the volume of each
chamber is decreased, the fuel oil is
pressurized and sent to pump chamber
B.
(3) Regulating valve

• Regulating valve (5) adjusts the feed
pump pressure so that the fuel oil pres-
sure in the pump chamber will be kept in
a specified range.
• If the injection pump speed rises, the
feed pump pressure rises, too. Then,
the fuel oil compresses regulating valve
spring (6) and pushes up piston (7). As
a result, the fuel oil is returned to suc-
tion side C of the feed pump as indicat-
ed by the arrows in the figure.
• Accordingly, the pump chamber pres-
sure can be adjusted by changing the
set force of regulative valve spring (6).
• The figure shows an example of the re-
lationship between the pump speed and
the pump chamber pressure. The hy-
draulic timer utilizes the pump chamber
pressure directly to control the injection
timing.
4D94LE, 4D98E 7-11

7-7 Operation of plunger
1) Drive shaft 7) Inlet slit 13) Outlet port

2) Drive gear 8) Plunger barrel 14) Plunger spring
3) Face cam 9) Plunger 15) Cut-off port
4) Control sleeve 10) Delivery valve spring 16) Cam disc
5) Magnet valve 11) Outlet slit 17) Roller
6) Inlet port 12) Delivery valve 18) Feed pump
(1) Operation
• Drive shaft (1) drives feed pump (18), cam disc (16), and plunger (9) simultaneously. Plunger spring
(14) presses plunger (9) and cam disc (16) against roller (17).
• If drive shaft (1) rotates cam disc (16), face cam (3) moves on roller (17) to reciprocate plunger (9).
When inlet port (6) of plunger barrel (8) fitted to the distributor head comes to inlet slit (7) of the plunger
(9), plunger (9) sucks and pressurizes the fuel oil.
• When outlet port (13) of plunger barrel (8) is connected to outlet slit (11) of the plunger, the high-pres-
sure fuel oil opens delivery valve (12) and is injected into the combustion chamber of the engine
through the nozzle.
• When cut-off port (15) of the plunger moves out of control sleeve (4), feeding of the fuel oil from plunger
(9) finishes.
7-12 4D94LE, 4D98E

1) Suction stroke
• When inlet port (6) of the plunger barrel
comes to inlet slit (7) of plunger (9) in the
lowering stroke of plunger (9), the fuel oil in
the pump chamber is sucked in the plunger.
A. Pressurizing chamber
2) Injection stroke
• If the cam disc starts rising, plunger (9)
starts turning. When plunger (9) blocks inlet
port (6) of the plunger barrel, feeding of the
fuel oil starts.
• When outlet slit (11) of plunger (9) comes to
outlet port (13) of the plunger barrel, the
high-pressure fuel oil pushes up delivery
valve (12). Then, the fuel oil is injected into
the combustion chamber of the engine
through the nozzle and nozzle holder.
4D94LE, 4D98E 7-13

3) End of injection
• When the cam disc raises plunger (9) fur-
ther and cut-off port (15) of plunger (9)
moves out of control sleeve (4), the high-
pressure fuel oil returns to the pump cham-
ber through cut-off port (15).
• As a result, the pressure of the fuel oil in the
plunger lowers below the set force of deliv-
ery spring (10). Accordingly, delivery valve
(12) closes and feeding of the fuel oil finish-
es.
4) Pressure equalizing stroke

• After injection finishes, when plunger (9)
turns 180° more, outlet slit (11) of the plung-
er comes to outlet port (13) of the plunger
barrel. As a result, the pump chamber is
connected to outlet port (13) and the fuel oil
pressures in them become equal to each
other.
• By this pressure equalizing stroke, the pres-
sure in outlet port (13) is equalized and the
spraying condition is stabilized.
• Strokes 1 – 4 described above are carried
out every turn of the crankshaft in the order
of the cylinders.
7-14 4D94LE, 4D98E

(2) Reverse revolution prevention mechanism

• While plunger (9) is revolving in the normal
direction, inlet port (6) of plunger barrel (8)
opens and fuel oil is sucked in plunger (9)
sufficiently in the plunger lowering stroke. In
the plunger rising stroke, inlet port (6) closes
and the fuel oil is injected.
• On the other hand, if the engine revolves in
reverse, inlet port (6) of plunger barrel (8)
does not close in the rising stroke of plunger
(9). Accordingly, the fuel oil is neither pres-
surized nor injected.
(3) Fuel injection rate control mechanism

• The fuel injection rate is changed by moving
control sleeve (4) to change the effective
stroke.
• The effective stroke means the stroke of the
plunger after inlet port (6) and inlet slit (7)
are closed until cut-off port (15) moves out
of control sleeve (4), which is in proportion
to the fuel injection rate.
• That is, if control sleeve (4) moves in left-
ward direction B as shown in the figure, ef-
fective stroke (S2) is reduced. If the former
moves in rightward direction C, effective
stroke (S1) is increased, or the injection rate
is increased.
• The position of the control sleeve (4) is de- B. Fuel injection rate is decreased
cided by controlling the governor. C. Fuel injection rate is increased
D. Effective stroke
4D94LE, 4D98E 7-15

(4) Delivery valve assembly

• The delivery valve assembly consists of de-
livery valve (12) and valve seat (19).
• If the pressure of the fuel oil sent from the
plunger becomes higher than the spring
force of delivery valve spring (10), delivery
valve (12) opens and the fuel oil is sent to
the nozzle and nozzle holder through the in-
jection pipe.
• After injection is finished, some pressure is
left in the injection pipe for the next injection.
Delivery valve (12) prevents the fuel oil in
the injection pipe from flowing back to the
plunger.
• If the residual pressure is too high, the fuel
oil may not stop sharply after injection is fin-
ished.
• The delivery valve sucks back the fuel oil in
the injection pipe by back suction stroke b of
piston a so that fuel oil stops sharply after
injection is finished.
A. Pressurizing stroke
B. Start of back suction (End of feeding of oil)
C. End of back suction
7-16 4D94LE, 4D98E

(5) Delivery valve holder with damping valve

• Delivery valve holder with damping valve (1)
prevents cavitation-erosion in the pipe in
high-speed operation, uneven injection, and
secondary injection.
• If high-pressure fuel oil is sent from the
plunger, delivery valve (5) and damping
valve open, and then the fuel oil is sent to
the nozzle mainly along the periphery of
damping valve (3). After injection is fin-
ished, damping vale (3) closes earlier than
delivery valve (5). Accordingly, the fuel oil
flows through only small orifice (6) of damp-
ing valve (3).
• As a result, the seating speed of delivery
valve (5) is lowered to prevent sharp drop of
the pressure in the pipe and suppress trans-
mission of the reflected waves in the pipe,
thus injection is stabilized.
a What is cavitation-erosion
• A phenomenon that oil pressure in a
pipe drops and bubbles are produced
locally is called cavitation.
• And a phenomenon that the pipe is
eroded by cavitation is called cavitation-
erosion.
1) Delivery valve holder

2) Damping valve spring
3) Damping valve
4) Delivery valve spring
5) Delivery valve
6) Orifice
A. While fuel oil is sent

B. While fuel oil is not sent
4D94LE, 4D98E 7-17

7-8 All speed governor
1) Drive shaft 12) Full load adjustment screw

2) Feed pump 13) Start spring
3) Governor shaft 14) Start lever
4) Flyweight holder gear 15) Governor lever assembly
5) Flyweight 16) Plunger
6) Flyweight holder 17) Spring
7) Control lever 18) Control sleeve
8) Governor spring 19) Governor sleeve
9) Idle spring 20) Cam disc
10) Collector lever 21) Drive gear
11) Tension lever
7-18 4D94LE, 4D98E

(1) Operation
• The structure of the all speed governor is shown in the figure at left. Revolution of drive shaft (1) is
transmitted to the speed increasing gear of flyweight holder (6) through drive gear (21), and then used
to rotate flyweight holder (6).
• Flyweight holder (6) is supported on governor shaft (3) and has 4 flyweights (5) in it, which are opened
outward by the centrifugal force.
• Flyweights (5) push governor sleeve (19) to push governor lever assembly (15) to the right. Governor
lever assembly (15) consists of collector lever (10), tension lever (11) and start lever (14).
• Fulcrum M1 of collector lever (10) is fixed with the pivot bolt of the pump housing. Since collector lever
(10) is pressed by lower spring (17) and upper full load adjustment screw (12), it does not move.
• Tension lever (11) and start lever (14) move around shaft M2 fixed onto collector lever (10).
• When the engine is started, start spring (13)
presses start lever (14) against governor
sleeve (19). Then, start lever (14) is turned
to the left around fulcrum M2 to move con-
trol sleeve (18) to the start increasing posi-
tion. While the engine is running, start lever
(14) and tension lever (11) keep in contact
with each other and move as one unit.
• Governor spring (8) is installed above ten-
sion lever (11) and connected to control le-
ver (7) through control lever shaft (22). The
set force of governor spring (8) can be
changed by adjusting the movement of con-
trol lever (7). Idle spring (9) is installed up-
per back side of tension lever (11).
• Accordingly, the governor is controlled in the
all revolution speed range by start spring
(13), governor spring (8), and idle spring (9).
• An example of the injection rate control
characteristics of the all speed governor is
shown in the figure.
4D94LE, 4D98E 7-19

(2) When engine is started
1) Idling stopper bolt 8) Tension lever M1: Fixed

2) Maximum speed stopper bolt 9) Start spring M2: Fulcrum
3) Control lever 10) Collector lever M3: Press fitted pin
4) Governor spring 11) Control sleeve
5) Governor sleeve 12) Plunger
6) Idle spring 13) Start lever
7) Full load adjustment screw 14) Flyweight
• When the engine is started, the fuel injection rate must be increased so that the engine starts easily.
While the engine is stopped, if the accelerator pedal is pressed, tension lever (8) is pulled to the left by
governor spring (4) until it reaches press fitted pin M3.
• At the same time, start lever (13) is separated from tension lever (8) by start spring (9) and pushes gov-
ernor sleeve (5) to the left. At this time, flyweight (14) is fully closed and start lever (13) turns around
M2 to move control sleeve (11) to start increasing position A (to the right).
• As a result, the engine can be started easily by pressing the accelerator pedal lightly.
7-20 4D94LE, 4D98E

(3) While engine is idling
• If the accelerator pedal is released after the engine is started, control lever (3) returns to the idling posi-
tion and the tension of the governor spring (4) is reduced to 0. Accordingly, flyweights (14) open out-
ward and push governor sleeve (5) to the right even if the engine is running at low speed.
• This movement turns start lever (13) to the right around M2 and moves control sleeve (11) in the fuel
reducing direction. When the centrifugal force of flyweight (14) is balanced with idle spring (6), idling
speed is stabilized.
4D94LE, 4D98E 7-21

(4) When full-load max. speed control is applied
• When the accelerator pedal is fully pressed and control lever (3) reaches maximum speed stopper bolt
(2), the tension of governor spring (4) becomes maximum and tension lever (8) is fixed to pin M3 press
fitted to the pump housing.
• At this time, idle spring (6) is fully compressed and start lever (13) and tension lever (8) become one at
point A and keep control sleeve (11) to the full load position.
• At this time, flyweight (14) is pressed and fully closed by governor sleeve (5).
7-22 4D94LE, 4D98E

(5) When no-load max. speed control is applied
• If the engine speed is increased and the centrifugal force of flyweights (14) exceeds the set force of
governor spring (4), governor sleeve (5) moves to the right and turns the governor lever assembly to the
right around M2.
• As a result, control sleeve (11) moves in the non-injection direction B (to the left) so that the engine
speed will not exceed the full-load maximum speed.
• If the accelerator pedal is not fully pressed, the set force of governor spring (4) changes freely. When
the engine is partially loaded, governor is controlled according to the set force of governor spring (4).
4D94LE, 4D98E 7-23

(6) Full load position adjustment mechanism

• The full load position is decided by the tight-
ening distance of full load adjustment screw
(7). If screw (7) is tightened, collector lever
(10) turns to the left (counterclockwise)
around fulcrum M1 of collector lever (10) to
move control sleeve (11) in the fuel increas-
ing direction A.
• If screw (7) is loosened, control sleeve (11)
moves in the fuel decreasing direction B.
7-24 4D94LE, 4D98E

7-9 Structure and operation of timer

(1) Structure
• The time lag in ignition in a diesel engine is increased as the engine speed is increased.
• To advance the injection timing of the injection pump and correct the time lag in ignition, a timer is in-
stalled to the bottom of the injection pump.
FIG. 1. While timer is not operating FIG. 2. While timer is operating
1) Drive shaft A. Low pressure side Revolving direction of drive shaft

2) Roller holder assembly B. High pressure side Revolving direction of roller holder
3) Timer piston C. High pressure chamber
4) Pin
5) Timer spring
6) Roller
7-26 4D94LE, 4D98E

(2) Operation (Standard automatic timer)

• As shown in the figure, the inside of the timer housing is divided by timer piston (3) into low pressure
side A and high pressure side B which receives the pump chamber pressure directly.
• Timer spring (5) having a set force is installed to low pressure side A. Timer piston (3) slides inside the
housing according to the change of the force of timer spring (5) and pressure in the pump chamber to
turn roller holder assembly (2) through pin (4).
• If the pump speed is increased and the pressure in the pump chamber exceeds the set force of timer
spring (5), timer piston (3) moves to compress the spring. (FIG. 2)
• The above movement turns roller holder assembly (2) in the opposite direction to the pump through pin
(4). As a result, the top of the cam disc approaches roller (6) of the roller holder quickly and the inject-
ing timing is advanced consequently.
• On the other hand, when the pump speed lowers and the force of timer spring (5) exceeds the pressure
in the pump chamber, timer piston (3) moves in the lagging direction.
4D94LE, 4D98E 7-27

7-10 Magnet valve
When magnet valve is ON When magnet valve is OFF
1) Magnet valve A. Fuel oil passage

2) Spring B. Inlet port
3) Armature
(1) Operation
• Magnet valve (1) is turned ON and OFF to open and close fuel oil passage A connected to inlet port B
of the plunger barrel, according to the operation of the ignition switch.
• If the ignition switch is turned ON, magnet valve (1) is turned ON and armature (3) is pulled up to open
fuel oil passage A.
• On the other hand, if the ignition switch is turned OFF, armature (3) is pushed down by spring (2) in it to
close fuel oil passage A.
• As a result, the fuel oil is not sent to the plunger and the engine is stopped immediately.
7-28 4D94LE, 4D98E

7-11 Improvement of startability at very low temperature

(4D94LE)
The startability of 4D94LE engine at very low tem-
perature can be improved by removing shim (1) at
starting fuel increase adjustment part A.
Shim (1): YM129930-61990
a After the above adjustment, the exhaust gas col-

or at start becomes bad a little.
4D94LE, 4D98E 7-29

7-12 Cold spark device (CSD) (4D98E)

Necessity of CSD
• The fuel injection timing of the 4D98E engine is (1)
delayed to meet the next emission regulations.
• As the fuel injection timing is delayed, the cold
startability is impaired.
• To solve this, the engines conformed to the next
emission regulations are equipped with the CSD
which senses the engine coolant temperature
and advances the injection timing when the tem-
perature is low and returns it to the normal when
the temperature exceeds a threshold value.
Outline
0001106A-02
• The CSD changes the oil pressure in the pump
chamber to control the injection timing of the in- 1) Cold spark device (CSD)
jection pump by being turned ON and OFF while
the engine is running.
• The CSD is a kind of actuator, which is turned 2 3
4 5
ON and OFF by a switch (coolant temperature
sensor) installed to the engine.
6
Structure
• The CSD consists of the magnet, spring, and
piston as shown in the figure at right. 11 10 9 8 7 023035-00J-A
• If the magnet is turned ON, the piston is pulled

2) Piston stroke 7) Filter element
by the magnet toward the left.
• The spring in the piston gives the piston a right- 3) To fuel inlet 8) Piston
ward force so that the piston will return to the ini- 4) To fuel tank 9) Spring
tial position. 5) Stopper 10) Housing
• There are two holes on the piston. When mag- 6) Pump room pressure 11) Magnet
net is OFF, those holes are matched with the
holes on the housing, and the fuel in the pump
chamber flows to the fuel inlet (low pressure
side).
Stroke (advance angle)
CSD: ON
Operation
• As the switch to turn ON and OFF the CSD, a
coolant temperature sensor is used.
• When the engine is started, if the coolant tem-
perature is below the set temperature, thermo OFF
switch is turned ON to turn ON the CSD to in-
crease the pressure in the pump chamber quick-
ly to advance the injection timing. Engine coolant temperature
• On the contraly, if the coolant temperature is 023036-00E
above the set temperature, the thermo switch is

turned OFF and the CSD does not operate and
the injection timing is advanced by the timer as
usual.
7-30 4D94LE, 4D98E

Shape of CSD coupler

• The shape of the CSD coupler is “YAZAKI Part
No. 7319-3311-30”. Prepare the wiring harness
coupler “YAZAKI Part No. 7318-3311-30” for the
forklift truck side.
023009-00X
CSD
023034-00E
4D94LE, 4D98E 7-31

Coolant temperature sensor function Operation chart

Stamp of manufacturer lot No. ST
(Durable black ink) (25.4) ST
Stamp of NTK Part No. ON ON
Starting switch ON
OFF
ON
Preheater lamp
22
7114-2100 (YAZAKI) OFF

(Mating part: 7316-2095, YAZAKI)
100 ± 10 ON
Glow plug OFF
Stamp of "NTK" t
ON
Valve OFF
AEXO.85 (black)
(1)
(When coolant temperature increases above 50°C) 023012-00E

(9)
7 2 0.5
6.5
Copper PK (YM124465-44950)
Function
25
M16×1.5 1. Engine preheater lamp

UP
• When the key is turned from OFF position to
8.5 DOWN
ON position, engine preheater lamp is light-
21 LEFT RIGHT ed up for a certain time.
023037-00E
• While the key is in START position, the en-
gine preheater lamp is lighted up.
Outside view of controller (If equipped)
55 34 6.5 2. Glow plug relay

Case • When the key is turned from OFF position to
ON position, the glow plug relay is turned
20
10
ON for a certain time. (Glow plug ON)

Label
• While the key is in START position, the glow
Vent hole on side
94.5
54.5
UP plug relay is turned ON. (Glow plug ON)
DOWN
3. CSD
• When the key is turned to ON position, if the
38 coolant temperature is below set tempera-
59
ture, the CSD is turned ON.
LEFT RIGHT Arrangement of connector terminals
• However, if the coolant temperature in-
FRONT Connector A Connector B creases above set value, CSD is turned
OFF.
REAR
Relay characteristics
(Waterproof)
Standard
Connector B6185-0025 (SUMITOMO) or equivalent Type Remarks
Mating part: 6195-0021 (SUMITOMO)
value
Contact
Character-
(Waterproof) Max. 0.2 V 40 A, after 30 seconds

voltage drop
istics
Connector A6185-0057 (SUMITOMO) or equivalent

Mating part: 6195-0060 (SUMITOMO) Insulation DC500V insulation
023010-00E Min. 1 Mz
resistance resistance tester
Connection diagram
Starting switch
OFF ON
ST Preheater lamp
Battery
DC12V
Coolant tempe- Valve

rature sensor
YM129107-44901
Glow plug
or equivalent 023011-00E
7-32 4D94LE, 4D98E

8. STARTING MOTOR
8. STARTING MOTOR
8-1 Specifications.......................................................................................................................................... 8-2

8-2 Components ........................................................................................................................................... 8-3
8-3 Troubleshooting ...................................................................................................................................... 8-4
8-4 Names of parts and disassembly procedure .......................................................................................... 8-5
8-5 Inspection and maintenance ................................................................................................................... 8-9
8-6 Assembly .............................................................................................................................................. 8-15
8-7 Characteristic test ................................................................................................................................. 8-18
4D94LE, 4D98E 8-1

8. STARTING MOTOR
8-1 Specifications
Manufacturer’s model (Hitachi) — S13-204
Part No. — YM129900-77040
Nominal output kW 2.3
Weight kg 5.5
Revolution direction (as viewed from pinion) — Clockwise
Engagement system — Magnetic shift

Terminal voltage / current V/A 11 / 140 or less
No-load
Revolution rpm 4,100 or above
Terminal voltage/current V/A 2.5 / 1,050 or less

Loaded
Torque Nm {kgf•m} 24.5 {2.5} or above
Clutch system — Overrunning
Pinion projection voltage (at 100°C) V 8.5 or less

Pinion DP or module / number of teeth — M3 / 9
Difference (O-ring, oil seal) — Dry type (none)
Spring force N {kg} 35 {3.6}
Brush Standard mm 15
Height
Limit mm 9
Series coil resistance z / °C 0.27 / 20

Magnetic switch
Shunt coil resistance z / °C 0.60 / 20
Standard mm 36.5
Outside diameter
Limit mm 35
Standard mm 0.03
Commutator Run-out
Limit mm 0.2
Standard mm 0.5 – 0.8

Insulation depth
Limit mm 0.2
Standard mm 0.03
Armature Run-out
Limit mm 0.02
Armature front — 6903DDU

Armature rear Normal — 608DDU
Bearing type
Pinion front number — 60004DDU
Pinion rear — 6904DDU

Pinion projection length mm 0.3 – 1.5
8-2 4D94LE, 4D98E

8. STARTING MOTOR
8-2 Components
(13)
(12) (14)
(11)
(10)
(9)
(8)
(7)
(6)
(5)
(4)
(23)
(3)
(2)
(1) (15)
(18)
(22)
(21)
(19)
(20)
(17)
(16) 0000103A
1) Pinion shaft 13) Magnetic switch assembly (solenoid)

2) M4 bolts (3 used) 14) Cover
3) Bearing retainer 15) M6 bolts (2 used)
4) Pinion clutch assembly 16) Armature assembly
5) Return spring 17) Field coil assembly
6) Pinion stop 18) Positive (+) brushes
7) Retaining ring 19) Negative (–) brushes
8) Gear housing 20) Brush holder assembly
9) Shift lever 21) Rear cover
10) Torsion spring 22) M5 through bolts (2 used)
11) Plunger 23) M4 bolts (2 used)
12) Dust covers (shims)
4D94LE, 4D98E 8-3

8-4
8-3
Is the shift lever at NO Move shift lever to Is battery fully charged NO • Charge or replace battery.
NEUTRAL position? NEUTRAL position. and terminals clean? • Clean terminals.
YES
Engine does not start? Inspect wiring up to magnetic switch
Is starter motor magnetic and repair if necessary.
NO • Key switch
8. STARTING MOTOR
switch actuating sound

YES heard? • Safety relay
• Magnetic switch assembly
NO NO • Electrical connections
Does engine crank? Is starter motor operating? YES
YES
• Adjust / pinion projection length.
Troubleshooting
• Inspect shift lever for deformation,

Pinion and ring gear NO return spring for fatigue and pinion
meshing normal? for sliding.
YES • Repair meshing between pinion and
ring gear or replace as needed..
YES
Connect M terminal of starter NO • Inspect brush and replace if worn.
Pinion roller clutch or motor directly to battery. • If brushes are not worn, replace armature
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.
YES
Magnetic switch assembly If starter motor becomes wet,replace magnetic switch

contact defective. Repair assembly even if function is normal.
NO or replace.
(slow revolution) NO
Is revolution normal? Is battery fully charged • Charge or replace battery. If a problem occurs:
and terminals clean? • Clean terminals. Immediately disconnect battery negative terminal.
YES YES
Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES
Does engine turn when YES Repair or replace Repair or replace key switch, starting
starter motor is replaced? starter motor. motor relay or magnetic switch assembly.
Slow Revolution
Inspect condition of engine.
0000102
4D94LE, 4D98E
8. STARTING MOTOR
8-4 Names of parts and disassembly procedure

Disassembling order
(1) Nut M8 (10)Dust cover
(Disconnect the connecting wire.) (11) Shift lever
aSee the disassembly drawing. (12)Screw M4 (3)
(2) Screw M4 (2) (13)Bearing retainer
(3) Through bolt M5 (2) (14)Gear case
(4) Rear cover (15)Pinion stopper clip
(5) Brush holder (16)Pinion stopper
(6) Yoke assembly (17)Return spring
(7) Armature (18)Pinion shaft
(8) Bolt M6 (2) (19)Clutch assembly
(9) Magnetic switch
Disassembly drawing
4D94LE, 4D98E 8-5

8. STARTING MOTOR
Disassembly procedure
1) Nut M8
Remove the magnetic switch nut M8 (12 mm),
and disconnect the connecting wire.
YE0478
a) Connecting wire
2) Screw M4 (2)
3) Through bolt M5 (2)
4) Rear cover
Remove the M4 screw fastening the brush
holder and remove through bolt M5 for rear
cover removal.
YE0479
5) Brush holder
Pull the brush spring up with the brush spring
puller. On the negative (–) side, bring the brush
spring into contact with the side of the brush for
lifting from the commutator surface. On the posi-
tive (+) side, extract the brush from the brush
holder.
YE0480
8-6 4D94LE, 4D98E

8. STARTING MOTOR
6) Yoke assembly
7) Armature
Remove the brush holder. The armature and
yoke assembly can now be removed.
YE0481
8) Bolt M6 (2)
9) Magnetic switch
Remove bolt M6 (10 mm), and the magnetic
switch can be removed.
YE0482
10) Dust cover

11) Shift lever
Take the dust cover out from the gear case. The
shift lever can be removed.
YE0483
4D94LE, 4D98E 8-7

8. STARTING MOTOR
12) Screw M4 (3)

13) Bearing retainer
14) Gear case
Remove Screw M4, and the bearing retainer and
clutch assembly can be removed.
YE0484
15) Pinion stopper clip

Remove the bearing retainer at the edge and a
the bearing, and shift the pinion stopper toward
the pinion. Use a plain (–) screwdriver and pry to
remove the pinion stopper clip.
b
YE0485
a) Pinion stopper clip

b) Plain (–) screwdriver
16) Pinion stopper

17) Return spring
18) Pinion shaft
19) Clutch assembly
Remove the pinion stopper clip. The pinion
stopper, return spring, pinion shaft and bearing
retainer can be removed.
YE0486
8-8 4D94LE, 4D98E

8. STARTING MOTOR
8-5 Inspection and maintenance

(1) Armature
(a) Commutator outside diameter
Measure the commutator outside diameter
and replace the commutator if the measured
value is less than the limit.
(Unit: mm)
Standard Limit
36.5 35.0
YE0487
(b) Armature coil continuity test

Check continuity between commutator seg-
ments with a multimeter. Good if continuity
exists. 1
(Coil disconnection)
No continuity
Replace the armature.
YE0488
1) Multimeter
(c) Armature coil insulation test

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

Continuity exists
YE0489
1) Multimeter
4D94LE, 4D98E 8-9

8. STARTING MOTOR
(d) Armature and commutator runout

Use a dial gauge and measure the armature
core runout and commutator runout. Correct
2
or replace if the limit is exceeded.
1
(Unit: mm)
Standard Limit
Armature 0.03 0.2
Commutator 0.03 0.2
YE0490
1) Commutator 2) Armature
(e) Commutator surface inspection

If the commutator surface is roughened,
grind with #500 to #600 emery cloth.
YE0491
(f) Commutator insulation depth

Measure the depth of the insulating material
between commutator segments, and correct
it if it is less than the limit.
3
(Unit: mm)
4
Standard Limit
5 8
0.5 – 0.8 0.2
6
7 9
YE0492
3) Hack-saw 7) Abnormal
4) Commutator 8) Chamfering
5) Commutator segment 9) Normal
6) Insulating material
8-10 4D94LE, 4D98E

8. STARTING MOTOR
(2) Field coil

(a) Field coil continuity test 1
Check continuity between field coil termi-
nals. Good if continuity exists.
(Coil disconnection)
No continuity
Replace the field coil.
YE0493
1) Multimeter
(b) Field coil insulation test

Check continuity between field coil terminal 1
and yoke. Good if no continuity exists.
(Coil short circuit)

Continuity exists
YE0494
1) Multimeter
(3) Brush
Measure the length of the brush. Replace with a
good one if the length is less than the limit.
(Unit: mm)
Standard Limit
15 9
YE0495
2) Brush
4D94LE, 4D98E 8-11

8. STARTING MOTOR
(4) Brush holder

(a) Brush holder insulation test
Check the continuity between the brush
holder (+ side) and base (– side) with a mul-
timeter. Good if no continuity exists.
Insulation defect
Continuity exists
Replace the brush holder.
1
YE0496
1) Multimeter
(b) Brush spring inspection

Inspect the brush spring pressure.
Standard spring pressure
31 – 39 N {3.1 – 3.9 kgf}
YE0497
(5) Magnetic switch

k When the starting motor is wetted with
water, always replace the magnetic switch
with a new even if the function is normal.
(a) Shunt coil continuity test

1
Check the continuity between the S terminal
and the switch body. Good if continuity
exists.
Coil disconnection
No continuity
Replace the magnetic switch.
YE0498
1) Multimeter
8-12 4D94LE, 4D98E

8. STARTING MOTOR
(b) Series coil continuity test

Check continuity between the S and M ter-
minals. Good if continuity exists.
Coil disconnection
No continuity Replace the magnetic
switch. 1
(c) Coil resistance test
Test Resistance at 20°C

Series coil 0.27 z
Shunt coil 0.60 z
YE0499
1) Multimeter
(d) Contact continuity test

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

No continuity Replace the magnetic
switch.
YE0500
1) Multimeter
(6) Pinion clutch

(a) Pinion inspection
Manually rotate the pinion. Inspect if it is
rotated smoothly in the driving direction, and
is locked in the opposite direction. Replace
the pinion clutch if abnormal.
YE0501
4D94LE, 4D98E 8-13

8. STARTING MOTOR
(b) Pinion sliding inspection

Check if the pinion slides smoothly in the
axial direction.
If damaged, rusted or heavy in sliding,
repair it.
If grease is applied too much on the pinion
shaft, sliding becomes heavy.
YE0502
(c) Ball bearing inspection

Rotate the ball bearing while holding the
outer race with fingertips. Inspect if it is
sticking or if there is play.
YE0503
8-14 4D94LE, 4D98E

8. STARTING MOTOR
8-6 Assembly
The assembly procedure is the reverse of the disassembly procedure, but pay attention to the following
points:
(1) Grease application points

• Gears in the gear case
• Shift lever operating portion
• Pinion sliding portion
• Magnetic switch plunger sliding portion
a Use the grease as C of HITACHI electrical equipment or equivalent for all the parts.
(2) Assembly of starting motor

1) Apply grease to the pinion shaft. Install
(4)
pinion shaft (5), pinion clutch assembly (1), (1)
return spring (4), and pinion stopper (3).
Install retainer ring (2) to the groove of the (5)
pinion shaft. Put piston stopper (3) on
retainer ring (2). (2)
(3)
2) Install the pinion clutch assembly to the
bearing retainer assembly. 0000112A
3) Install the bearing retainer assembly and

pinion assembly to the gear housing.
Tighten three M4 bolts.
4) Apply grease to the sliding parts of shift

lever (6). Install torsion spring (7), shift lever, (8)
dust cover (8), plunger (9), and magnetic
switch assembly (10).
(7)
(6)
(10)
(9)
0000268-A
5) Install the magnetic switch to the gear

housing. Pull out the pinion from the gear
h ou s in g s o tha t th e m ag ne ti c sw it ch
assembly can be installed.
6) Using the two M6 bolts, install the magnetic

switch assembly to the gear housing.
0000131
4D94LE, 4D98E 8-15

8. STARTING MOTOR
7) Carefully install armature coil assembly (11)

to field coil assembly (12).
(11)
(12)
0000269-A
8) Fit the brush spring to the brush holder.

Install the brush to the brush holder. If the
brush is installed reversely, the starting
motor rotates in reverse. Take care of its
direction.
0000106
9) Carefully install the brush holder assembly

to the armature assembly.
10) Install the field coil assembly with the

armature assembly to the gear housing.
11) Install the rear cover to the brush holder

assembly. Tighten the two bolts securely.
12) Install the two M4 through bolts. Tighten

them to the specified torque.
13) Connect the wiring to the magnetic switch

assembly. Tighten M8 nuts. Install the cover
over the wiring.
0000104
8-16 4D94LE, 4D98E

8. STARTING MOTOR
(3) Pinion projection length

Connect the positive (+) lead from the battery to
terminal S and negative (–) lead to terminal M.
Turn the switch ON and measure the pinion
moving distance l in the thrust direction.
Perform this test within 10 seconds.
Standard
l 0.3 – 1.5 mm
a Before measuring the dimension, pull the

pinion out lightly in the direction of the
arrow.
YE0506
If the measured l dimension is outside the stan-

dard range, either insert or remove the dust 1
cover (adjusting shim 0.5 mm, 0.8 mm) for
adjustment.
YE0507
1) Dust cover (adjusting shim: 0.5 mm, 0.8 mm)
4D94LE, 4D98E 8-17

8. STARTING MOTOR
8-7 Characteristic test

Since the characteristics can be checked roughly by means of a simple no-load test as explained below.
a Complete the test quickly since the rating of the starting motor is 30 seconds.
1. No-load test
Fix the starting motor on a test bench and connect wiring as shown in the following figure. When the switch
is closed, a current flows in the starting motor, which is rotated at no-load. Measure the current, voltage and
rotation speed at this time, and check if they satisfy the specified characteristics.
1) Ammeter
2) Voltmeter
3) Battery
Terminal voltage (V) / Max. 11 / 140

current (A)
Revolution (rpm) Min. 4,100
8-18 4D94LE, 4D98E

9. ALTERNATOR
9. ALTERNATOR
9-1 Sectional view......................................................................................................................................... 9-2

9-2 Troubleshooting ...................................................................................................................................... 9-3
9-3 Parts names and disassembly procedure............................................................................................... 9-4
9-4 Testing and maintenance ....................................................................................................................... 9-7
9-5 Assembly .............................................................................................................................................. 9-11
9-6 Performance test .................................................................................................................................. 9-14
4D94LE, 4D98E 9-1

9. ALTERNATOR
9-1 Sectional view
12
11
10
9
6 8
5
7
2 3
23
1 27
19 22
20
21
13 25 26
24
18
17
16
15
14 0001671A
1) Nut 15) Bolt

2) Pulley 16) Holder
3) Collar 17) IC regulator assembly
4) Front frame housing 18) Bolt
5) Stator assembly 19) Nut
6) Stud 20) Insulation bushing
7) Front frame housing bearing 21) Bolt
8) Bearing cover 22) Spring
9) Bearing cover bolt 23) Brush holder
10) Rotor assembly 24) Brush
11) Rear frame housing bearing 25) Bolt
12) Thrust washer 26) Rear cover
13) Nut 27) Bolt
14) Rear frame housing
9-2 4D94LE, 4D98E

9-2
Turn key switch ON. NO Disconnect harness L terminal Ground drive machine side NO
Does battery indicator and IG terminal at alternator L terminal. Does battery Replace the battery indicator.
4D94LE, 4D98E
turn ON? indicator turn on?
YES
YES Inspect rotor assembly and
brushes.
Start Engine.
Inspect or replace V-belt.

Battery indicator ON. Inspect alternator.
Troubleshooting
At idle, does battery NO

Battery indicator flashes. Inspect diode positive (+) side.
indicator turn OFF?
YES
Battery indicator
is dim.
Increase engine speed to
1500 rpm. Turn light switch ON.
Battery voltage minus

L terminal voltage is Excessive voltage drop between
greater than 0.5 volt. BAT and batt ( + side) terminal.
Does battery indicator NO Battery indicator With engine idling,
come ON? is dim. measure voltage at L
terminal and at battery.
Battery voltage minus Check condition of L terminal.
YES L terminal voltage is Inspect diode negative (-) side.
less than 0.5 volt.
With engine running at 1500
rpm, measure voltage at Battery voltage greater
than 15.5 volts. Replace regulator.
battery.
Battery voltage NO
is between 13 With engine idling, Does battery indicator Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?
YES
Notes: Not abnormal.
1) Use a fully charged battery
2) DC voltmeter: 0 to 30 V, 0.5 class
3) The check method is also applicable to the bench test 0001666E-A
9-3
9. ALTERNATOR
9. ALTERNATOR
9-3 Parts names and disassembly procedure

Disassembly procedure
(1) Nut (15) Insulation bushing
(2) Pulley (16) Bolt
(3) Collar (17) Nut
(4) Bolt (18) Stud
(5) Rear cover (19) Rear frame housing
(6) Bolt (20) Front frame housing
(7) Brush holder (21) Rotor assembly
(8) Spring (22) Stator assembly
(9) Brush (23) Bearing cover bolt
(10) Bolt (24) Bearing cover
(11) Bolt (25) Front frame housing bearing
(12) IC regulator assembly (26) Rear frame housing bearing
(13) Holder (27) Thrust washer
(14) Nut
Disassembly drawing
27
26
21
23
18 24
22
20
25
2 3
7
1 4
14 8
15
11
17 6 5
9
10
12
13
16
19 0001671A-A
9-4 4D94LE, 4D98E

9. ALTERNATOR
Disassembly procedures
1) Remove nut (1) from the shaft of the rotor
assembly. Remove pulley (2).
(2)
(1)
0001673A
2) Remove three bolts (4) that are fixing the rear

frame assembly to rear cover (5) and the nut
that is fixing terminal B. (7)
(4)
3) Remove brush holder (7). Remove brush spring
(8) and brush (9).
(8) (5)
(9)
0001674A-A
4) Remove the three bolts that are fixing regulator

assembly (12) to holder (13). (14)
k
(15)
If bolts of wrong length are used for assem-
bly, they touch the rear frame and the regu-
lator cannot be controlled. An excessive
voltage is applied to the battery, which may
be damaged seriously.
(12)
5) Remove the bolts that are fixing holder (13) to (13)
the rear frame housing. Remove holder (13).
0001675A-A
6) Remove nut (14) that is fixing insulation bushing
(15). Remove insulation bushing (15).
k When removing the bushing, take care not
to stretch the stator wiring. If it is stretched,
the stator may be damaged.
7) Remove four bolts (16) and four nuts (17) that

are fixing the rear frame housing to front frame
housing.
(17)
(16)
0001676A-A
4D94LE, 4D98E 9-5

9. ALTERNATOR
8) Before removing the stator from the front frame

housing, draw positioning line (b) on the housing (a)
to match with the position of lead wires (a). The
positioning line must not deviate more than
±0.5 mm.
When installing a new stator, match it with posi-
tioning line (b) of the removed stator. The new
stator must not deviate from the positioning line
of the removed stator more than ±0.5 mm.
(b)
0001773-A
9) When replacing the front frame housing, make

positioning lines (c) at two places before disas-
sembly. Positioning lines (c) must not deviate
more than ±1 mm. If the positioning lines devi-
ate, the lead wires of the stator cannot be con-
nected to the rectifier.
(c) 0001774-A
10) Using a press, remove rotor assembly (21) from

front frame housing (20) and rear frame housing
(19).
k Take care not to drop the rotor. If it falls, the
slip ring and fan may be damaged.
(19)
(21)
(20)
0001677A-A
11) Remove stator assembly (22) from the front

(24)
frame housing.
12) When bearing (25) of the front frame housing

needs to be replaced, remove four bolts (23) (23)
that are fixing bearing cover (24) to the front
frame housing. Remove bearing cover (24). (25)
Using a puller, remove bearing (25). Discard
removed bearing (25).
(22)
0001678A-A
13) When bearing (26) of the rear frame housing

needs to be replaced, remove it with a puller.
Discard bearing (26) and thrust washer (27).
(27)
(26)
0001679A-A
9-6 4D94LE, 4D98E

9. ALTERNATOR
9-4 Testing and maintenance

(1) Stator coil
(a) Continuity test of stator coil
Using tester (1), measure the resistance
between the terminals of the stator coil. (1)
Standard value Max. 1 z
(b) Insulation resistance test of stator coil

Using DC500V insulation resistance tester
(1), test the insulation between coil terminal
and core. 0001759
Standard value Min. 1 z
(1) 0001760
(2) Rotor
(a) Check of slip ring surface
When the slip ring surface is roughened or
dirty, polish it with sandpaper of #300 –
#500.
(b) Resistance test of slip ring

Using tester (1), measure the resistance
between the terminals of the stator coil.
(c) Insulation resistance test of slip ring

(1)
Using DC500V insulation resistance tester
(3), test the insulation between rotor core (1) (2)
and slip ring (2).
(3) 0001761
4D94LE, 4D98E 9-7

9. ALTERNATOR
(d) Measurement of outside diameter of slip ring

Measure the outside diameter of the slip
ring.
Standard value 14.4 mm

Replacement standard
14.0 mm
value
0001762
(3) Rectifier
Using tester (3) set in range K, check the conti-
nuity.
(1)
If normal, there is continuity in only one direc-
tion.
k Do not use a DC500V insulation resistance
tester to test the rectifier.
If it is used, the rectifier is broken.
k The condition of the rectifier cannot be
judged by only the resistance in the correct
direction. Judge by the difference in the re-
sistance.
(2)
1) Circuit
2) Testing
3) Tester (3)
0001763
9-8 4D94LE, 4D98E

9. ALTERNATOR
(4) IC regulator
The following is the description of Model M1 IC regulator.
Wiring diagram
L1:
Power Supply
12V 3.4W
Variable DC
(Charge Light L2:
Substitute) 12V 3.4W
(Rotor Coil
Terminal E Substitute)
0001775E-A
L3: 12V 3.4W
(Reverse Side of the IC Regulator)
(Electrothermal Choke Substitute)
No. Procedure Voltage Indicator Remarks

1 Connection
2 Set the variable DC power supply to 12 V. Turn SW1 and SW2 to OFF and SW3 to ON.
L1: ON Charge lamp lights up
3 Turn SW1 (starting switch) to ON. 12 V L2: (Dim) ON Initial energizing
L3: OFF
L1: OFF Testing of charge lamp
Turn SW2 to ON
4 12 V L2: ON Testing of electric power generation
(while engine is running).
L3: ON Testing of electric heat choke
L1: OFF
Turn SW1 and SW2 to ON and
5 14.5 ± 0.6 V L2: OFF Check of output voltage
increase voltage slowly from 12 V.
L3: ON
L1: ON
6 Return voltage to 12 V. 12 V L2: ON
L3: ON
Other functions
Turn SW1 and SW2 to ON, and SW3 to L1: ON
Warning for over-voltage
7 OFF, and perform step 5 to increase 16.5 ± 1.0 V L2: OFF
voltage slowly. L3: OFF
With SW1 and SW2 at ON, turn SW3 to L1: ON
8 ON, and decrease voltage slowly from Max. 10 V L2: ON Warning for voltage drop
12 V. L3: ON
L1: ON Warning for disconnection of termi-
Return voltage to 12 V and disconnect
9 12 V L2: ON nal S
terminal S.
L3: OFF
Test diode.
10
(See Chapter 9, 9-4, (5))
4D94LE, 4D98E 9-9

9. ALTERNATOR
(5) Diode
Using tester (1), check continuity between termi-
nals B and F.
1) Disconnect the diode wiring between
terminals B and F.
2) Set the tester to the Xz range and measure (1)

the continuity between terminals B and F.
No continuity Replace diode
3) Change the polarities of terminals B and F

and measure the continuity again.
(2) 0001764
Continuity Replace diode
1) Tester
2) Testing of diode
(6) Brush
Measure length (L) of the part of the brush pro-
jected from the brush holder.
Standard value 10.5 mm
Replacement standard value 8.4 mm

L
0001765-A
9-10 4D94LE, 4D98E

9. ALTERNATOR
9-5 Assembly
Carry out assembly in the reverse order to disassembly, observing the following.
(1) Assembly of brush holder
1) Insert tab (1) of brush holder (4) in groove (1) (2)
(2) of holder cover (3).
k Before assembling the brush holder, in- (3)
stall the IC regulator to the alternator.
(4) 0001766
2) Install brush holder (4) to IC regulator (5). (4)
3) Keep interval (L) to 1.2 mm or larger.

L
4) Tighten inside bolt (6).
(6)
(5) 0001768-A
5) Fit the housing securely to groove (6) on the

reverse side of brush holder cover (3).
k If the housing is not installed correctly
to the brush holder cover, the brush
holder cover may catch the rotor shaft
and sealing effect may not be obtained.
(3)
0001770-A
(6)
6) Align the groove of the holder cover with the

tab of the brush holder. (Part A) A B
7) Take care that the inside of the holder cover

is not caught. (Part B)
0001769-A
4D94LE, 4D98E 9-11

9. ALTERNATOR
8) Bring the two brushes in secure contact with

the slip ring on the rotor shaft.
9) Press as shown in (F) and tighten with two

bolts (7).
Tightening torque
Target
value Min. value Max. value
Display of
SI unit system 1.96 1.57 2.35
(Nm)
(7)
Display of conven-
tional unit system 20 16 24
{kgf•cm}
F 0001772-A
(2) Assembly of alternator

1) If thrust washer (27) has been removed,
install it to the rear frame housing. Apply
lubricating oil to outside of new bearing (26).
Push bearing (26) into the rear frame
housing.
(27)
2) If bearing (25) of the front frame housing (26)
0001679A-A
has been removed, apply lubricating oil to
the outside of new bearing (25). Push
bearing (25) into the front frame housing. (24)
Install bearing cover (24) to the front
housing. Tighten four bolts (23).
(23)
3) Install stator assembly (22) to the studs of
the front frame housing. (25)
4) Apply lubricating oil to the shaft of rotor

assembly (21). Push rotor assembly (21) (22)
into front frame housing (20) and rear frame
housing (19). 0001678A-A
k Take care not to drop the rotor. If it

falls, the slip ring and fan may be dam-
aged.
5) Align the front frame housing and rear frame

housing. Install four bolts (16) and four nuts
(17).
(19)
(21)
(20)
0001677A-A
(17)
(16)
0001676A-A
9-12 4D94LE, 4D98E

9. ALTERNATOR
6) Install insulation bushing (15) and nut (14).

(14)
(15)
(12)
(13)
0001675A-A
7) Install rear cover (5) to the rear frame

housing with three bolts (4).
(7)
(4)
(8) (5)
(9)
0001674A-A
8) Install pulley (2) and nut (1) to the shaft of

the rotor assembly. Tighten nut (1).
(2)
(1)
0001673A
4D94LE, 4D98E 9-13

9. ALTERNATOR
9-6 Performance test

(1) Bench test
1) Prepare a test bench and check that the
charge lamp is lighting up.
(1)
(9) (2)
2) Place alternator (1) on the test bench.
(3)
3) Insert the test connector of main wiring
harness (6) in alternator (1).
(6) (4)
4) Connect main wiring harness (6) and sub (8)
wiring harness C (7). (5)
(7)
0001776
5) Connect voltmeters (2) and (3) and
ammeter (5) as shown in the figure. 1) Alternator
2) Positive (+) side of voltmeter
6) Turn SW1 to ON position and check that 3) Negative (–) side of voltmeter
main wiring harness lamp (charge lamp) (8)
4) To negative (–) terminal of battery
lights up.
5) To positive (+) terminal of ammeter
7) Turn ON the test bench motor and increase 6) Main wiring harness
its speed and check that charge lamp (8) 7) Sub wiring harness C
goes off. 8) Charge lamp
9) Terminal B
9-14 4D94LE, 4D98E

9. ALTERNATOR
(2) Wiring for test

Wiring diagram of alternator with model M regulator
L1
(CHG Light) S1 S2
rpm
L2
(Electrothermal Choke)
0001777E-A
Wiring diagram of alternator with model GS regulator
L1
(CHG Light) S1 S2
rpm
0001778E-A
Wiring diagram of alternator with model D regulator
L1
(CHG Light) S1 S2
rpm
0001779E-A
Wiring diagram of alternator with model GL regulator
L1
(CHG Light) S1 S2
Always wire the CHG light.

rpm
0001780E-A
4D94LE, 4D98E 9-15

9. ALTERNATOR
(3) Check of output voltage

1) Turn ON battery switch S1.
2) Operate the alternator. When output current

exceeds 0 A, turn ON load switch S2. Regulated Voltage Range
3) Adjust the rotation speed and load to the

standard values.
Regulated Voltage
4) Check that the voltage is within the standard
range.
k The output voltage has the tempera-
ture characteristics shown in the figure.
Perform measurement quickly.
Temperature of IC Regulator
0001781E-A
(4) No-load test

1) Turn ON battery switch S1.
2) Operate the alternator. When output current

exceeds 0 A, turn OFF S1.
3) Adjust the rotation speed and voltage to the

standard values.
4) Check that the rotation speed is within the

standard range.
(5) Output test

1) Turn ON battery switch S1, and then turn
ON load switch S2.
2) Operate the alternator.
3) While adjusting the rotation speed and load

resistance, set the rotation speed and
voltage to the standard value.
4) Check that the output current is within the

standard range.
9-16 4D94LE, 4D98E

10. SPECIAL SERVICE TOOLS
10-1 Special tools ......................................................................................................................................... 10-2

10-2 Measuring instruments ......................................................................................................................... 10-4
4D94LE, 4D98E 10-1

10-1 Special tools
No. Tool name Applicable model and tool size Illustration
(Unit: mm)
L1 L2 d1 d2
Valve guide tool
1
(for extracting valve guide) 20 75 7.5 11
0000827
a Locally manufactured
(Unit: mm)
L1 L2 d1 d2
Valve guide tool
2
(for inserting valve guide) 15 65 14 20
0000828
(Unit: mm)
Connecting rod bushing
L1 L2 d1 d2
replacer
3
(for removal/installation of 20 100 30 33
connecting rod bushing)
a Locally manufactured 0000829
Valve spring compressor Part No.

4 (for removal/installation of
valve spring) YM129100-92630 0000830
(Unit: mm)
L1 L2 L3 d1 d2 d3
Valve stem seal inserter
5
(for inserting valve stem seal) 17 65 4 16.2 22 13.5
0000820
Filter wrench
6 (for removal/installation of Available on the market
filter)
0000821
10-2 4D94LE, 4D98E

No. Tool name Applicable model and tool size Illustration
(Unit: mm)
Camshaft bushing tool L1 L2 d1 d2
7 (for extracting camshaft
bushing) 18 70 50 –0.3
–0.6 53 –0.3
–0.6
0000822
Engine Applicable
name Part No. bore
Flex-Hone
8 (For re-honing of cylinder 4D94LE YM129400-92430 83 – 95 mm
liner)
4D98L YM129400-92440 89 – 101 mm
0000823
Part No.
Piston insertion tool
9 YM95550-002476
(for inserting piston)
a The above piston insertion tool is applicable 0000824
to f60 – f125 mm diameter pistons.
Piston ring replacer

10 (for removal/installation of Available on the market
piston ring)
0000825
Mounting tool for crankshaft

pulley
11 a Locally manufactured
(For mounting crankshaft
pulley)
0000826
4D94LE, 4D98E 10-3

10-2 Measuring instruments
No. Instrument name Application Illustration
Measurements of shaft bending, and strain

1 Dial gauge
and gap of surfaces
0000831
Measurements of narrow or deep portions

2 Test indicator
that cannot be measured by dial gauge
0000832
For holding the dial gauge when measuring

3 Magnetic stand using a dial gauge, standing angles adjust-
able
0000833
For measuring the outside diameters of

4 Micrometer
crankshaft, pistons, piston pins, etc.
0000834
For measuring the inside diameters of cylin-

5 Cylinder gauge
der liners, connecting rod metal, etc
0000835
For measuring outside diameters, depth,

6 Calipers
thickness and width
0000836
7 Depth micrometer For measuring of valve sink

0000837
For measuring valve spring inclination and

8 Square
straightness of parts
0000838
10-4 4D94LE, 4D98E

9 V-block For measuring shaft bend
0000839
For tightening nuts and bolts to the specified

10 Torque wrench
torque
0000840
For measuring gaps between piston ring and

11 Thickness gauge
ring groove, and shaft joints during assembly
0000841
12 Cap tester For checking cooling water leakage
0000842
For checking concentration of antifreeze and

13 Battery coolant tester
the battery electrolyte charge status
0000843
For measuring injection spray pattern of fuel

14 Nozzle tester
injection nozzle and injection pressure
0000844
15 Digital thermometer For measuring temperatures
0000845
4D94LE, 4D98E 10-5

For measuring revolution by contacting

Contact type
the mortise in the revolving shaft
0000846
For measuring revolution by sensing the

1
reflecting mark on the outer periphery of the
revolving shaft
Photoelectric type
1) Revolving shaft
Speedometer
2) Reflection mark 2 0000847

16
Measures the revolution regardless of the

center or periphery of the revolving object. 3
Fuel high-pressure pipe
clamp type
3) High-pressure pipe
YE0560-A
For measuring resistance, voltage and conti-

17 Circuit tester
nuity of electrical circuits
0000848
For measuring compression pressure
Compression gauge kit Part No.
YMTOL-97190080
0000849
18
Adapter for direct injection 2-valve cylinder

head
New compression test
adapter Part No.
130
YM119802-92950
0000850
10-6 4D94LE, 4D98E

11. SERVICE STANDARDS
11-1 Engine tuning........................................................................................................................................ 11-2

11-2 Engine body .......................................................................................................................................... 11-3
11-3 Lubricating oil system (trochoid pump) ................................................................................................. 11-7
11-4 Tightening torques for main parts ......................................................................................................... 11-8
4D94LE, 4D98E 11-1

11-1 Engine tuning
Reference
No. Inspection item Unit Standard Limit page
1 Gap at intake/exhaust valve heads mm 0.15 – 0.25 — 3-4
V-belt tension Used part mm 10 – 14 — 3-3

2 Finger pressure:
98 N {10 kg} New part mm 8 – 12 — 3-3
3 Fuel injection pressure MPa 11.8 – 13.2 {120 – 135} — 3-6

{kg/cm2}
Fuel injection timing degrees
4 6±1 — 3-9
(When plunger 1 mm lifted) (A.T.D.C.)
Specification/Model — 4D94LE 4D98E — —
5 No-load revolution Max. rpm 2,450 ± 25 2,725 ± 25 — —
Min. rpm 810 ± 25 850 ± 25 — —

MPa 2.35
6 Compression (at 250 rpm) {kgf/cm2} 2.84 – 3.04 {29 – 31} {24} 2-7
7 Top clearance mm 0.733 – 0.873 — —
8 Cooling water capacity l 4.2 (engine only) — —

Upper limit of
Lubricating oil oil level gauge l 7.5 — —
9 capacity
(oil pan) Lower limit of l 5.5 — —
oil level gauge
MPa
Max. (in cold state) 0.59 {6.0} or less — —
{kgf/cm2}
Lubricating oil MPa
10 pressure At rated output {kgf/cm2} 0.29 – 0.39 {3.0 – 4.0} — —
At idling MPa 0.06 {0.6} or above — —

{kgf/cm2}
11 Oil pressure switch operating pressure MPa 0.05 ± 0.01 {0.5 ± 0.1} — —
{kgf/cm2}
12 Thermostat valve opening temperature °C 69.5 – 72.5 — 3-11
11-2 4D94LE, 4D98E

11-2 Engine body

(1) Cylinder head
(1-1) Cylinder head
Reference
Inspection item Unit Standard Limit
page
Combustion surface distortion mm Max. 0.05 0.15 4-6
Intake mm 0.5 – 0.7 1.0 4-6
Valve sink
Exhaust mm 0.6 – 0.8 1.1 4-6
Intake mm 1.3 2.0 4-6
Seat width
Valve seat Exhaust mm 2.2 3.0 4-6
Intake Deg. 120 — 4-10
Seat angle
Exhaust Deg. 90 — 4-10
Seat correction angle Deg. 1 40, 2 150 — 4-10
(1-2) Intake/exhaust valve and guide
Reference
page
Valve stem outside diameter mm 7.965 – 7.980 7.90 4-7
Intake Valve guide inside diameter mm 8.015 – 8.030 8.10 4-7
Valve clearance mm 0.035 – 0.065 0.18 4-7
Valve stem outside diameter mm 7.965 – 7.970 7.90 4-7
Exhaust Valve guide inside diameter mm 8.015 – 8.030 8.10 4-7
Valve clearance mm 0.045 – 0.075 0.18 4-7
Valve guide driving-in method — Cold-fitted — 4-11
Valve guide projection from cylinder head mm 14.7 – 15.0 — 4-11
Projection of valve stem seal from cylinder head mm 16.7 – 17.0 — 4-11
Replacement valve guide inside diameter after insert mm 8.015 – 8.030 — 4-7, 11
(1-3) Valve spring
Reference
Page
Free length mm 47.5 — 4-8
Inclination mm — 1.2 4-8
Load for compressing uneven pitch portion by 1 mm N {kgf} 22.1 {2.257} — —
(1-4) Rocker arm and shaft
Reference
Inspection item Unit Standard Limit page
Rocker arm shaft hole diameter mm 18.50 – 18.52 18.57 4-9
Rocker arm shaft outside diameter mm 18.47 – 18.49 18.42 4-9
Clearance mm 0.01 – 0.05 0.15 4-9
4D94LE, 4D98E 11-3

(1-5) Push rod
Inspection item Unit Standard Limit Reference

page
Bend mm — 0.03 4-9
(2) Gear Train and Camshaft

(2-1) Camshaft

page
End play mm 0.05 – 0.20 0.30 4-15
Bending (1/2 of the dial gauge reading) mm 0 – 0.02 0.05 4-16
Cam height mm 42.435 – 42.565 42.185 4-16
Camshaft outside diameter mm 49.925 – 49.950 49.890 4-16
Gear side Bushing inside diameter mm 49.990 – 50.055 50.130 4-16
Clearance mm 0.040 – 0.130 0.240 4-16
Intermediate Block inside diameter mm 50.000 – 50.025 50.100 4-16
Clearance mm 0.065 – 0.115 0.225 4-16
Flywheel side Block inside diameter mm 50.000 – 50.025 50.100 4-16
Clearance mm 0.050 – 0.100 0.210 4-16
(2-2) Idle gear shaft and bushing

Reference
page
Shaft outside diameter mm 45.950 – 49.975 45.900 4-17
Bushing inside diameter mm 46.000 – 46.025 46.075 4-17
Clearance mm 0.025 – 0.075 0.175 4-17
(2-3) Backlash of each gear
Reference
Crank gear, cam gear, idle gear, fuel injection pump
mm 0.08 – 0.14 0.16 4-13
gear and PTO gear
Lubricating pump gear mm 0.09 – 0.15 0.17 4-13
11-4 4D94LE, 4D98E

(3) Cylinder block

(3-1) Cylinder block

page
4D94LE mm 94.000 – 94.030 94.130 4-22
Inner diameter
4D98E mm 98.000 – 98.030 98.130 4-22
Cylinder bore
Roundness mm 0.01 or less 0.03 4-22
Cylindricity mm 0.01 or less 0.03 4-22
(3-2) Crankshaft
Reference
Bending (1/2 of the dial gauge reading) mm — 0.02 4-23
Pin outside diameter mm 57.952 – 57.962 57.902 4-24
Metal inner diameter mm 58.000 – 58.026 — 4-24
Crank pin Metal thickness mm 1.492 – 1.500 — 4-24
US 0.25 mm mm 1.617 – 1.625 — 4-24
Clearance mm 0.038 – 0.074 0.150 4-24
Journal outside diameter mm 64.952 – 64.962 64.902 4-24
Metal inner diameter mm 65.000 – 65.020 — 4-24
Crank journal Metal thickness mm 1.995 – 2.010 — 4-24
US 0.25 mm mm 2.125 – 2.130 — 4-24
Clearance mm 0.038 – 0.068 0.150 4-24
(3-3) Thrust bearing
Reference
Crankshaft end play mm 0.11 – 0.21 0.28 4-20
mm 1.930 – 1.980 1.880 4-20
Thrust bearing thickness
OS 0.25 mm mm 2.055 – 2.105 — 4-20
4D94LE, 4D98E 11-5

(3-4) Piston and ring

page
4D94LE mm 93.945 – 93.955 93.900 4-25
OS 0.25 mm mm 94.190 – 94.205 — 4-25
OS 0.50 mm mm 94.445 – 94.705 — 4-25
Piston outside OS 1.00 mm mm 94.945 – 94.955 — 4-25

diameter 4D98E mm 97.940 – 97.950 97.900 4-25
OS 0.25 mm mm 98.185 – 98.200 — 4-25
OS 0.50 mm mm 98.445 – 98.705 — 4-25
OS 1.00 mm mm 98.945 – 98.955 — 4-25
Clearance with cylinder bore
Note) Measure at 22 mm above the piston bottom mm 0.050 – 0.080 0.120 4-25
face in vertical direction to the piston pin.
Piston outside diameter mm 29.989 – 30.000 29.959 4-26
Piston pin Hole inside diameter mm 30.000 – 30.009 30.039 4-26
Clearance mm 0.000 – 0.020 0.080 4-26
Piston ring groove width mm 2.040 – 2.060 — 4-27
Piston ring width mm 1.940 – 1.960 1.920 4-27
Top ring
Piston side clearance mm 0.080 – 0.120 — 4-27
Piston end clearance mm 0.250 – 0.450 0.540 4-27
Piston ring groove width mm 2.080 – 2.095 2.195 4-27
Second ring
Piston side clearance mm 0.090 – 0.125 0.245 4-27
Piston ring groove width mm 3.015 – 3.030 3.130 4-27
Oil ring
Piston side clearance mm 0.025 – 0.060 0.180 4-27
11-6 4D94LE, 4D98E

(3-5) Connecting rod

page
Thrust clearance mm 0.13 – 0.23 — 4-19
Bushing inside diameter mm 30.025 – 30.038 30.068 4-29
Small end of Piston pin outside diameter mm 29.987 – 30.000 29.959 4-29
connecting rod
Clearance mm 0.025 – 0.051 0.109 4-29
(3-6) Tappet
Reference
Tappet stem outside diameter mm 11.975 – 11.990 11.955 4-30
Tappet hole (block) inside diameter mm 12.000 – 12.018 12.038 4-30
Clearance mm 0.010 – 0.043 0.083 4-30
11-3 Lubricating oil system (trochoid pump)
Reference
page
Clearance between outer rotor and gear case mm 0.100 – 0.155 0.25 5-4
Side clearance between outer rotor and gear case mm 0.05 – 0.10 0.15 5-4
Outer rotor to inner rotor tip clearance mm — 0.16 5-4
Shaft outer diameter mm 12.925 – 12.970 12.915 5-4
Rotor shaft and
gear case Bearing inside diameter mm 12.980 – 13.020 13.050 5-4
Clearance mm 0.010 – 0.065 0.105 5-4
4D94LE, 4D98E 11-7

11-4 Tightening torques for main parts

Nm {kgm}
Nominal Reference
Tightening position Tightening torque
size page
Thermostat case M8 22.5 – 28.4 {2.3 – 2.9} 6-3
Intake manifold M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Exhaust manifold M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Cylinder head Bonnet M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Valve arm support M10 44.1 – 53.9 {4.5 – 5.5} 4-3
(*1) Fuel injection nozzle M6 6.9 – 8.8 {0.7 – 0.9} 4-3
Engine hoisting hook M8 22.5 – 28.4 {2.3 – 2.9} 4-3
(*2) Cylinder head M11 103.0 – 112.8 {10.5 – 11.5} 4-5
Gear case M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Idle gear shaft M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Camshaft thrust bearing M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Oil pan M8 22.5 – 28.4 {2.3 – 2.9} 4-18
M10 44.1 – 53.9 {4.5 – 5.5}
Cylinder block Flywheel housing 4-18
M8 22.5 – 28.4 {2.3 – 2.9}
(*2) Bearing cap M11 107.9 – 117.7 {11.0 – 12.0} 4-20
Lubricating oil suction pipe M8 22.5 – 28.4 {2.3 – 2.9} 4-18
PTO lubrication pipe M8 12.7 – 16.7 {1.3 – 1.7} 4-18
Fuel injection pump inlet pipe M8 12.7 – 16.7 {1.3 – 1.7} 4-12
Fuel injection pump rear stay M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Cooling water pump M8 17.6 – 22.5 {1.8 – 2.3} 6-2
Alternator M10 44.1 – 53.9 {4.5 – 5.5} 4-3
Gear case cover M8 17.6 – 22.5 {1.8 – 2.3} 4-12
Fuel injection pump M10 34.3 – 44.1 {3.5 – 4.5} 4-12
Gear case Oil pan M8 17.6 – 22.5 {1.8 – 2.3} 4-18
Lubricating oil pump ass’y M8 17.6 – 22.5 {1.8 – 2.3} 5-2
Fuel injection pump drive gear
M8 17.6 – 22.5 {1.8 – 2.3} 4-12
cover
PTO Lubrication pipe M8 12.7 – 16.7 {1.3 – 1.7} 4-12
(*2) Flywheel M14 186.3 – 205.9 {19 – 21} 4-15
Crankshaft
(*2) Crankshaft pulley M14 107.9 – 127.5 {11 – 13} 4-13
Connecting rod (*2) Connecting rod bolt M10 53.9 – 58.8 {5.5 – 6.0} 4-19
Mounting flange Starting motor M12 78.4 – 98.0 {8.0 – 10.0} 4-12
Main bearing cap Lubricating oil suction pipe stay M8 22.5 – 28.4 {2.3 – 2.9} 4-18
Intake manifold Fuel filter M10 34.3 – 44.1 {3.5 – 4.5} 4-3
11-8 4D94LE, 4D98E

Nm {kgm}
Nominal Reference
Tightening position Tightening torque
size page
Cooling water
Cooling fan M8 17.6 – 22.5 {1.8 – 2.3} 4-3
pump
Fuel injection pipe M12 19.6 – 24.5 {2.0 – 2.5} 4-3
Delivery valve holder — 58.8 – 68.6 {6.0 – 7.0} 7-3
(*1) Drive gear M14 49 – 53 {5.0 – 5.4} 7-5
Fuel pipe (inlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-3
Fuel injection pump
Fuel pipe (return) M14 19.6 – 24.5 {2.0 – 2.5} 7-3
Fuel feed pump M6 7.8 – 9.4 {0.8 – 0.96} 7-3
Oil inlet pipe M10 9.8 – 12.7 {1.0 – 1.3} 4-12
Rear stay M10 44.1 – 53.9 {4.5 – 5.5} 4-12
Fuel injection noz- Fuel injection pipe M12 19.6 – 24.5 {2.0 – 2.5} 4-3
zle Nozzle holder — 39.2 – 44.1 {4.0 – 4.5} 3-5
Fuel pipe (inlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-9
Fuel pipe (outlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-9
Fuel feed pump
Priming pump M16 39.2 – 44.1 {4.0 – 4.5} 7-9
Plug M26 78.4 – 98.0 {8.0 – 10.0} 7-9
Fuel pipe M12 24.5 – 34.3 {2.5 – 3.5} 4-3
Fuel filter
Fuel return pipe M14 39.2 – 44.1 {4.0 – 4.5} 4-3
Alternator Stay M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Marked (*1): Important bolt

(*2): Apply lubricating oil.
4D94LE, 4D98E 11-9

4D94LE, 4D98E ENGINE
Form No. 4D94E17-BE2
Product Support Div.

110 Yokokurashinden, Oyama, Tochigi 323-8567, Japan
PRINTED IN JAPAN

4d94e17 Be2 1

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4D94E17-BE2

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

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

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

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

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

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

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

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

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

00-2 4D94LE, 4D98E

1-1 Specifications.......................................................................................................................................... 1-2

4D94LE, 4D98E 1-1

Engine name — 4D94LE 4D98E

Engine specification class — For standard forklift truck

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

Cylinder bore x stroke mm 94 x 110 98 x 110

Displacement l 3.053 3.318

rpm 2,200 2,450

HP SAE 45.8 59.2

Max. speed at no load (Bare engine) rpm 2,450 ± 25 2,725 ± 25

Low idle speed (Bare engine) rpm 810 ± 25 845 ± 25

Dry engine weight* kg 225

Power take-off position — Flywheel side

Direction of rotation — Counterclockwise (viewed from flywheel)

Cooling system — Radiator

1-2 4D94LE, 4D98E

1-2 Fuel oil, lubricating oil and cooling water

4D94LE, 4D98E 1-3

1-3 Engine performance curve

200 162 N·m/1,500 rpm

34.2 kW/2,200 rpm

260 Fuel consumption 20

Engine Speed rpm

1-4 4D94LE, 4D98E

4D98E [Applicable machine: FD20H/25H/30H/35A-17]

44.1 kW/2,450 rpm

Engine Speed rpm

4D94LE, 4D98E 1-5

1-4 Engine external views

1) Starting motor 7) Fuel injection pump

1-6 4D94LE, 4D98E

12) Crankshaft pulley

4D94LE, 4D98E 1-7

1-5 Structural description

1) Intake manifold 9) Tappet

1-8 4D94LE, 4D98E

16) Water pump 20) Flywheel

4D94LE, 4D98E 1-9

1-6 How to read this manual

(2) How to Read the Explanations

• Disassembly procedure • Operation Points

Operation point to be explained on a later page.

1-10 4D94LE, 4D98E

• Contents omitted in this manual

(3) Definition of Terms

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

T.D.C. top dead center

B.D.C. bottom dead center

rpm revolutions per minute

3 Bolt/nut tightening torque

4D94LE, 4D98E 1-11

1-7 Precautions for service work