Service Manual
Table Of Contents
- BINDING
- INTRODUCTION
- How to use this manual
- Safety Cautions
- Fire and explosion
- Stay clear of all rotating and moving parts
- Be careful of burns
- Be careful of exhaust fume poisoning
- Protect ears from noises
- Be careful of falling down
- Be careful of handling fuel, engine oil and LLC
- Service battery
- When abnormality occurs
- Other cautions
- Modification of engine prohibited
- Never break the seals
- Pre-operational check and periodic inspection/maintenance
- Break-in operation
- Warming-up operation
- Avoid engine operations in a overload condition
- Cooling operation before stopping engine
- Protection of engine against water entry
- Maintenance of air cleaner or pre-cleaner
- Observe safety rules at work site
- Work clothing and protective gear
- Use of tools optimum for each work
- Avoidance of prolonged time of starter operation
- Do not turn off battery switch during operation
- Cautionary instructions for transporting engine
- Avoid continuous engine operation in a low load condition
- Ventilation of engine room
- Avoid contact with high-pressured fuel
- About warning labels
- GENERAL CONTENTS
- GENERAL
- SERVICE DATA
- SERVICE TOOLS
- DETERMINATION OF OVERHAUL
- DISASSEMBLY OF BASIC ENGINE
- 1. Disassembling and inspecting cylinder head and valve mechanism
- 2. Disassembling and inspecting flywheel
- 3. Disassembling and inspecting damper, gear case, timing gear and camshaft
- 3.1 Removing crankshaft pulley and damper
- 3.2 Removing cover
- 3.3 Removing timing gear case
- 3.4 Measuring timing gear backlash
- 3.5 Measuring idler gear and camshaft gear end play
- 3.6 Removing fuel injection pump
- 3.7 Removing oil pan
- 3.8 Removing oil strainer
- 3.9 Removing oil pump gear
- 3.10 Removing idler gear
- 3.11 Removing PTO drive gear
- 3.12 Removing camshaft
- 3.13 Separating camshaft gear
- 3.14 Installing camshaft gear and thrust plate
- 3.15 Removing front plate
- 3.16 Removing oil pump
- 4. Disassembling and inspecting piston, connecting rod, crankshaft and crankcase
- INSPECTION AND REPAIR OF BASIC ENGINE
- 1. Inspecting and repairing cylinder head and valve mechanism
- 1.1 Measuring clearance between rocker bushing and rocker shaft
- 1.2 Measuring valve stem outside diameter and valve guide inside diameter
- 1.3 Replacing valve guide
- 1.4 Inspecting valve face
- 1.5 Refacing valve face
- 1.6 Refacing valve seat
- 1.7 Replacing valve seat
- 1.8 Lapping valve and valve seat
- 1.9 Measuring perpendicularity and free length of valve spring
- 1.10 Measuring distortion of the bottom surface of the cylinder head
- 1.11 Measuring push rod runout
- 1.12 Removing combustion jet
- 2. Inspecting and repairing flywheel
- 3. Inspecting and repairing timing gear and camshaft
- 3.1 Measuring timing gear backlash
- 3.2 Measuring idler gear and camshaft gear end play
- 3.3 Measuring cam lift
- 3.4 Measuring camshaft runout
- 3.5 Measuring camshaft journal outside diameter
- 3.6 Measuring camshaft bushing inside diameter
- 3.7 Replacing camshaft bushing
- 3.8 Measuring idler bushing inside diameter and idler shaft outside diameter
- 3.9 Replacing idler shaft
- 3.10 Measuring clearance between tappet and tappet guide hole
- 3.11 Inspecting tappet
- 3.12 Inspecting V-belt groove wear
- 3.13 Inspecting damper
- 4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase
- 4.1 Measuring crankcase top surface distortion
- 4.2 Measuring cylinder inside diameter
- 4.3 Measuring piston outside diameter
- 4.4 Measuring piston ring end gap
- 4.5 Measuring clearance between piston ring groove and piston ring
- 4.6 Measuring piston pin bore diameter and piston pin outside diameter
- 4.7 Measuring piston protrusion
- 4.8 Measuring clearance between connecting rod bearing and crankpin
- 4.9 Measuring clearance between connecting rod bushing and piston pin
- 4.10 Replacing connecting rod bushing
- 4.11 Inspecting connecting rod bend and twist
- 4.12 Inspecting connecting rod bearing
- 4.13 Measuring connecting rod end play
- 4.14 Weight difference of connecting rod assembly in one engine
- 4.15 Measuring crankshaft journal outside diameter
- 4.16 Measuring crankshaft crankpin outside diameter
- 4.17 Grinding crankshaft
- 4.18 Measuring crankshaft end play
- 4.19 Measuring crankshaft runout
- 4.20 Replacing crankshaft gear
- 4.21 Inspecting oil seal contact surface
- 4.22 Installing oil seal sleeve
- 4.23 Removing oil seal sleeve
- 4.24 Inspecting main bearing surface
- 4.25 Measuring clearance between main bearing and crankshaft journal
- 1. Inspecting and repairing cylinder head and valve mechanism
- REASSEMBLY OF BASIC ENGINE
- 1. Reassembling piston, connecting rod, crankshaft and crankcase
- 1.1 Installing main bearing
- 1.2 Installing thrust plate
- 1.3 Installing tappet
- 1.4 Installing crankshaft
- 1.5 Installing main bearing caps
- 1.6 Inserting side seal
- 1.7 Installing main bearing cap bolt
- 1.8 Measuring crankshaft end play
- 1.9 Reassembling piston and connecting rod
- 1.10 Installing piston ring
- 1.11 Preparation for installing pistons
- 1.12 Installing connecting rod bolt and connecting rod bearing
- 1.13 Installing pistons
- 1.14 Installing connecting rod cap
- 2. Reassembling timing gear and camshaft
- 2.1 Installing oil pump
- 2.2 Installing front plate
- 2.3 Installing camshaft gear and thrust plate
- 2.4 Installing camshaft
- 2.5 Installing PTO drive gear
- 2.6 Installing idler gear
- 2.7 Installing oil pump gear
- 2.8 Installing fuel injection pump
- 2.9 Inspecting and adjusting timing gear after installation
- 2.10 Installing front oil seal
- 2.11 Installing timing gear case
- 2.12 Installing oil strainer
- 2.13 Installing oil pan
- 2.14 Installing cover
- 2.15 Installing crankshaft pulley and damper
- 3. Reassembling flywheel
- 4. Reassembling cylinder head and valve mechanism
- 4.1 Cleaning cylinder head bottom surface
- 4.2 Installing valve stem seal
- 4.3 Installing valve and valve spring
- 4.4 Installing cylinder head gasket
- 4.5 Installing cylinder head assembly
- 4.6 Tightening cylinder head bolts
- 4.7 Inserting push rod
- 4.8 Reassembling rocker shaft assembly
- 4.9 Installing rocker shaft assembly
- 4.10 Determining top dead center of No. 1 cylinder compression stroke
- 4.11 Adjusting valve clearance
- 4.12 Installing rocker cover
- 1. Reassembling piston, connecting rod, crankshaft and crankcase
- FUEL SYSTEM
- 1. Removing fuel system
- 2. Disassembling, inspecting and reassembling fuel system
- 2.1 Disassembling and inspecting fuel filter
- 2.2 Changing fuel filter
- 2.3 Disassembling and inspecting fuel injection nozzle
- 2.4 Inspecting and adjusting fuel injection valve opening pressure
- 2.5 Inspecting fuel spray pattern of fuel injection nozzle
- 2.6 Cleaning and inspecting nozzle tip
- 2.7 Reassembling fuel injection nozzle
- 2.8 Inspecting and cleaning gauze filter of distribute type fuel injection pump
- 3. Installing fuel system
- LUBRICATION SYSTEM
- 1. Removing lubrication system
- 2. Disassembling, inspecting and reassembling lubrication system
- 2.1 Disassembling and inspecting oil pump
- 2.2 Inspecting oil pump
- 2.2.1 Measuring clearance between outer rotor and inner rotor
- 2.2.2 Measuring end play of rotor and pump case
- 2.2.3 Measuring clearance between outer rotor and pump case
- 2.2.4 Measuring clearance between main shaft and pump case
- 2.2.5 Measuring clearance between main shaft and bushing
- 2.2.6 Installing oil pump bushing
- 2.3 Reassembling oil pump
- 2.4 Disassembling and inspecting oil cooler
- 2.5 Inspecting oil filter
- 2.6 Inspecting relief valve
- 2.7 Inspecting safety valve
- 3. Installing lubrication system
- COOLING SYSTEM
- INLET AND EXHAUST SYSTEMS
- ELECTRICAL SYSTEM
- 1. Removing electrical system
- 2. Disassembling, inspecting and reassembling electrical system
- 2.1 Inspection before disassembling starter
- 2.2 Disassembling and inspecting starter
- 2.3 Inspecting and repairing starter
- 2.3.1 Inspecting brushes for wear
- 2.3.2 Measuring brush spring load
- 2.3.3 Inspecting brush holder for insulation
- 2.3.4 Measuring commutator radial runout
- 2.3.5 Measuring commutator outside diameter
- 2.3.6 Measuring undercut depth
- 2.3.7 Checking armature coil
- 2.3.8 Inspecting field coil
- 2.3.9 Inspecting rear bracket
- 2.3.10 Inspecting overrunning clutch operation
- 2.3.11 Inspecting front bracket
- 2.3.12 Inspecting gears of starter
- 2.3.13 Inspecting magnetic switch
- 2.3.14 Inspecting starter relay
- 2.4 Reassembling starter
- 2.5 Disassembling and inspecting alternator
- 2.6 Inspecting and repairing alternator
- 2.7 Reassembling alternator
- 2.8 Inspecting glow plug
- 2.9 Inspecting magnetic valve (stop solenoid)
- 2.10 Installing magnetic valve (stop solenoid)
- 3. Installing electrical system
- ADJUSTMENT AND OPERATION
- 1. Adjusting engine
- 2. Break-in operation
- 3. Performance test (JIS standard)
