REPAIR MANUAL For 3 Cylinder LiquidĆCooled Diesel Engines FORM MS-1055-5/02 2002 BRIGGS & STRATTON DAIHATSU LLC PRINTED IN U.S.A.
1 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 1 General Information Section Contents Page ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 IN THE INTEREST OF SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ENGINE VIEWS . . . . . . . . . . .
1 GENERAL INFORMATION IN THE INTEREST OF SAFETY This safety alert symbol indicates that this message involves personal safety. Signal words danger, warning and caution indicate hazard degree. Death, personal injury and/OR property damage may occur unless instructions are followed carefully. WARNING: DO NOT 1. DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odorless and deadly poison. 2. DO NOT place hands or feet near moving or rotating parts. Keep all guards in place. 3.
1 GENERAL INFORMATION ENGINE VIEWS Diesel 1 2 3 13 12 1. 2. 3. 4. 5. Thermostat Oil filler cap Electric starter Oil pan Alternator 4 5 6 7 11 6. 7. 8. 9. 10. 11. 12. Injector nozzle Glow plug Oil drains 10 Oil filter Dipstick Injector pump 9 Engine Date code xxxxxxxx 13. Engine Model & Type number xxxxxx xxxx-xx 8 Turbo-charged Diesel 1. 2. 3. 4. 5. 6. Thermostat Oil filler cap Turbocharger Electric starter Alternator Oil pan 7. 8. 9. 10. 11. 12. 13. 14. 15.
1 GENERAL INFORMATION ENGINE SPECIFICATIONS 582447 @58A447 @588447 Diesel, 4-cycle, 3 cylinder, in-line, liquid cooled OHV, gear driven 68 x 64 68 x 78 72 x 78 (2.680 x 2.520) (2.680 x 3.070) (2.834 x 3.070) 697 (42.5) 850 (52.0) 952 (58.1) 1-2-3 (front, center, back) 24.0:1 25.0:1 24.4:1 @ 24.
1 GENERAL INFORMATION Cylinder Head Type Material Combustion Chamber Valve seat angle Intake Single piece casting Cast Iron Swirl Type 45° 45° Opens 10° BTDC Valve Intake Closes 45° ABDC Specifications Valve timing Opens 45° BBDC Exhaust Closes 10° ATDC Intake mm (in) 0.20 (.008 in) Valve clearance (cold) Exhaust mm (in) 0.20 (.
1 GENERAL INFORMATION LUBRICATING SYSTEM Lubricating Method Oil Pump Oil Filter Pressure lube Type Trochoid Drive Gear drive Type Full flow, paper Oil Capacity 3.3 ltr (3.5 qt) Oil Pump Relief Valve Opening Pressure 4.6 Bar (65 psi) Lubrication Oil API SE/CD class or higher COOLING SYSTEM Cooling Method Liquid cooled, forced circulation Coolant Capacity (engine only) Approximately 1.8 ltr (1.9 qt) Cooling System Pressure 1.0-0.75 Bar (15-11 psi) Pressure Cap Capacity 0.
1 GENERAL INFORMATION TABLE 1 Injection Pump Timing Engine Date Code Before 99010100 Model/Type No. Timing Specification 432447-0150-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0105-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0106-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0107-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0108-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0109-E2 0.93 ± .03 mm (.0365” ± .001”) 582447-0105-E2 0.93 ± .03 mm (.0365” ± .001”) 582447-0125-E2 0.81 ± .03 mm (.032” ± .
1 INJECTOR PUMP IDENTIFICATION IDENTIFICATION CODE 7 : 700 cc 8 : 850 cc 9 : 950 cc NAME PLATE DESTINATION U : USA J : Japan X : Except for USA SERIAL NUMBER IDENTIFICATION CODE TABLE 3 Engine Speed Specification Chart Pump Mfg. Part No. ID Code Model & Type No.
1 GENERAL INFORMATION Description Wrench/Socket Size Torque Alternator Adjust. Bracket 12 mm 19.0 Nm (170 in. lbs.) Alternator – 14 Amp (to bracket) 12 mm 19.0 Nm (170 in. lbs.) Alternator – 40 Amp (to bracket) 12 mm 61.0 Nm (45 ft. lbs.) Alternator Bracket (to block) 12 mm 19.0 Nm (170 in. lbs.) Camshaft Gear 17 mm 41.0 Nm (30 ft. lbs.) Camshaft Retainer 10 mm 8.0 Nm (70 in. lbs.) Conn. Rod Nuts 12 mm 36.0 Nm (320 in. lbs.) Crankshaft Pulley 19 mm 88.0 Nm (65 ft. lbs.) Cyl.
1 GENERAL INFORMATION BRIGGS & STRATTON DAIHATSU NUMERICAL NUMBER SYSTEM All Briggs & Stratton Daihatsu engines have a unique numerical designation system. Each engine is identified by a Model, Type and Code/Serial number. Example: Model Type Code/Serial 432447 0125 01 020521145 This chart explains the numerical model designation system. It is possible to determine most of the important mechanical features of the engine by merely knowing the model number. Here is how it works.
1 GENERAL INFORMATION MAINTENANCE SCHEDULE More frequent service is required when operating in adverse conditions (note 4 below).
2 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 2 Cylinder Head and Valves Section Contents Page REMOVE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DISASSEMBLE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSPECT AND REPAIR Cylinder Head . . . . . . . . . . . . . . . . . . . .
2 CYLINDER HEAD AND VALVES REMOVE CYLINDER HEAD ALWAYS disconnect fuel shut off solenoid wire from injection pump before checking compression, to prevent accidental starting. A Drain cooling system and disconnect radiator hoses. 1. Remove the following parts from engine, Fig. 1-Fig. 5: B a. Alternator adjusting bracket screw b. V-belt c. Fan (if equipped) C Fig. 1 – Remove V-belt And Fan Fig. 2: d. Water pump e. Exhaust manifold NOTE: Remove exhaust system before removing exhaust manifold.
2 CYLINDER HEAD AND VALVES Fig. 5: k. Fuel injector nozzles l. Glow plugs L K Fig. 5 – Remove Glow Plugs And Injectors 2. Set No. 1 piston at TDC, Fig. 6: REFERENCE POINT a. Rotate crankshaft pulley until timing mark on pulley is aligned with reference point on timing cover. b. If intake and exhaust valves have clearance, No. 1 piston is at TDC – compression stroke. c. If intake and exhaust valves do not have clearance, turn crankshaft pulley one complete revolution. Valves will then have clearance.
2 CYLINDER HEAD AND VALVES 3 5 4 DISASSEMBLE CYLINDER HEAD 6 9 10 8 1 11 7 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Cylinder Head Assembly Cylinder Head Gasket Valve Stem Cap Valve Spring Retainer Locks Valve Spring Retainer Valve Spring Valve Valve Spring Seat Valve Stem Seal Valve Guide Combustion Chamber Fig. 9 – Cylinder Head Components Remove valves, Fig. 10. 1. Use valve spring compressor, Tool #19417, to compress valve springs. Remove the following parts, Fig. 9: a. b. c. d. e.
2 CYLINDER HEAD AND VALVES INSPECT AND REPAIR STRAIGHT EDGE 1. Check cylinder head mounting surfaces, Fig. 12 and Fig. 13. Be sure all gasket material is removed from surfaces before checking. Use a gasket scraper if necessary. a. Inspect cylinder head for cracks or damage. b. Use a straight edge and check cylinder head lower surface for distortion. Fig. 12 – Check Cylinder Head For Distortion Fig. 13: c. Check intake and exhaust manifold mounting surfaces.
2 CYLINDER HEAD AND VALVES 3. Install combustion chamber, Fig. 16. Align locating projection on combustion chamber with groove in cylinder head. Use a soft hammer and drive in new combustion chamber until it bottoms. COMBUSTION CHAMBER Fig. 16 – Install Combustion Chamber CHECK AND REPAIR VALVE GUIDES 1. Check valve guide bushings for wear using reject gauge, Tool #19382, Fig. 17. Remove if damaged or if reject gauge enters valve guide. REJECT GAGE Fig. 17 – Check Valve Guide Bushing 2.
2 CYLINDER HEAD AND VALVES 3. Using bushing driver, Tool #19416, press in new valve guide bushing until tool bottoms on cylinder head, Fig. 19. Fig. 19 – Installing Valve Guide Bushing VALVES AND SEATS 1. Valve faces may be resurfaced to 45°. See Fig. 20 for dimensions for valves. Lap valves and seats with valve lapping Tool, #19258 and valve lapping compound, Tool #94150. 1.0 mm (.040”) MINIMUM 0.8 mm TO 1.2 mm (1/16” TO 3/64”) SEATING AREA CENTERED ON VALVE FACE Fig. 20 – Valve Dimensions 2.
2 CYLINDER HEAD AND VALVES 4. Inspect valve stem cap for wear, Fig. 23. Replace if cap is worn recessed. Fig. 23 – Check Valve Stem Cap 5. Check valve springs for squareness and free length, Fig. 24. Replace if out of square more than 1.0 mm (.040 in.). Replace if free length is less than 30.7 mm (1.209 in.). Fig. 24 – Check Valve Springs DISASSEMBLE ROCKER ARM SHAFT 1. Remove snap rings from ends of rocker arm shaft. Remove set screw from center rocker arm support. Disassemble rocker arm assembly.
2 CYLINDER HEAD AND VALVES 2. Check rocker arms and shaft, Fig. 26. a. Check rocker arm-bearing surface. Replace if greater than 10.03 mm (0.395 in.). b. Check rocker arm shaft Replace if less than 9.96 mm (0.392 in.). c. Check rocker arm studs for stripped threads and replace if required. Fig. 26 – Checking Rocker Arm And Shaft ASSEMBLE ROCKER ARM SHAFT 1. Oil all components before assembling. Small grooves in rocker shaft next to oil holes must face down.
2 CYLINDER HEAD AND VALVES ASSEMBLE CYLINDER HEAD 12 3 4 11 5 6 13 9 1 10 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cylinder Head Cylinder Head Gasket Valve Stem Cap Valve Spring Retainer Locks Valve Spring Retainer Valve Spring Valve Valve Spring Seat Valve Stem Seal Valve Guide Push Rod Rocker Arm Assembly Rocker Arm Stud NOTE: When replacing rocker arm studs, torque to 20.0 Nm (180 in. lbs.). 7 2 Fig. 28 – Cylinder Head Components 1. Install new valve stem seals, Fig. 29.
2 CYLINDER HEAD AND VALVES 2. Install valve spring seats, Fig. 30. NOTE: Lightly coat valve stems with Valve Guide Lubricant #93963 before installing valves. 3. Install valves. VALVE SPRING SEATS Fig. 30 – Install Valve Spring Seats And Valves 4. Install valve springs with valve spring compressor, Tool #19417, Fig. 31. NOTE: After installing valve spring retainer locks, tap valve spring retainer lightly with a soft hammer to ensure locks are seated. Fig.
2 CYLINDER HEAD AND VALVES 3. Lubricate push rods with engine oil then install with recessed end up, Fig. 34. RECESSED END UP Fig. 34 – Install Push Rods 4. Install valve stem caps on valve stems. Install rocker arm assembly, Fig. 35. Install washers and torque nuts to 19.0 Nm (170 in. lbs.). NOTE: Make sure rocker adjustment studs are seated in recessed end of push rods. Fig. 35 – Install Rocker Arm Assembly 5. Install intake manifold with new gasket, Fig. 36. a. Torque screws to 8.0 Nm (70 in. lbs.
2 CYLINDER HEAD AND VALVES 7. Install exhaust manifold with new gasket, Fig. 38. a. Torque screws to 19.0 Nm (170 in. lbs.). Fig. 38 – Install Exhaust Manifold GENERAL ASSEMBLY 1. Install water pump with new gasket, Fig. 39. a. Torque screws and nuts to 19.0 Nm (170 in. lbs.). Fig. 39 – Install Water Pump 2. Install water pump pulley, Fig. 40. 3. Install fan (if equipped). a. Torque screws to 7.0 Nm (60 in. lbs.). Fig. 40 – Install Water Pump Pulley And Fan 4. Install V-belt, Fig. 41.
2 CYLINDER HEAD AND VALVES ADJUST VALVES REFERENCE POINT 1. Before adjusting valves, make sure that No. 1 cylinder is at TDC – compression stroke, Fig. 42. TIMING MARK Fig. 42 – Set Cylinder No. 1 at TDC a. Adjust valves and check, Fig. 43. Valve Clearance (cold) IN and EX 0.20 mm (0.008 in.) b. Torque adjusting screws and jam nuts to 11.0 Nm (95 in. lbs.). Fig. 43 – Adjust Valve Clearances With No.
3 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 3 Timing Gears and Gear Case Section Contents Page REMOVE TIMING GEAR COVER AND GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHECKING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVE GEAR CASE . . . . . . . . . . . .
3 TIMING GEARS AND GEAR CASE REMOVING TIMING GEAR COVER AND GEARS Make sure that #1 cylinder is at TDC, compression stroke. See Section 2, Fig. 6. Remove V-belt and fan (if equipped). Drain oil from engine. NOTE: Clean areas around fuel lines and injectors to prevent dirt entry. 1. Remove the following parts, Fig. 1. a. Glow plug wiring. b. Glow plugs. c. Injector pump bracket. d. Remove fuel delivery lines. A D B C Fig. 1 – Remove Fuel Delivery Lines 2. Remove the following parts, Fig. 2. a.
3 TIMING GEARS AND GEAR CASE 6. Remove oil pump drive gear, Fig. 5. a. Check oil pump drive gear for damaged teeth. OIL PUMP GEAR Fig. 5 – Removing Oil Pump Gear CHECKING GEARS Inspect gear teeth for wear or damage. CHECK GEARS IN SEQUENCE SHOWN. 1. Check gear backlash between idler gear and crankshaft gear using dial indicator as shown in Fig. 6. a. Set tip of indicator on gear tooth, then rock idler gear back and forth noting indicator reading. NOTE: Crankshaft must not turn while checking.
3 TIMING GEARS AND GEAR CASE 4. Hold idler gear as shown and check gear backlash between injector pump timing gear and idler gear using dial indicator, Fig. 9. Injector pump timing gear backlash must not exceed 0.2 mm (.008”). NOTE: Idler gear must not turn while checking. If gears are worn it is recommended that they be replaced as a set. Fig. 9 – Checking Injector Pump Timing Gear Backlash REMOVE GEAR CASE O-RING 1. Remove injector pump timing gear with a three jaw puller, Fig. 10. a.
3 TIMING GEARS AND GEAR CASE REPLACE TIMING GEAR COVER OIL SEAL 1. Drive out oil seal. 2. Use seal driver, Tool #19423, to install new oil seal, Fig. 13. Fig. 13 – Replacing Oil Seal ASSEMBLE TIMING GEAR CASE AND GEARS 1. Clean and lubricate oil pump rotor with engine oil and install in cylinder block, Fig. 14. a. ID mark on rotor must face cylinder block. ID MARK OIL PUMP ROTOR Fig. 14 – Installing Oil Pump Rotor 2. Install timing gear case with new gasket. Install camshaft retainer, Fig. 15.
3 TIMING GEARS AND GEAR CASE 4. Assemble idler gear shaft with arrow up, as shown in Fig. 17. ARROW UP Fig. 17 – Installing Idler Gear Shaft Engine models 432000 and 582000 after date code 990111007, and all engine models 522000 are equipped with right angle helical timing gears. Timing marks are identified by letters (A, AA, B, BB, etc.), instead of numbers. The timing procedure is the same. 5.
3 TIMING GEARS AND GEAR CASE 8. Install crankshaft pulley with timing mark at 12 o’clock position (#1 cylinder), Fig. 21. NOTE: Be sure alignment pin in crankshaft gear is seated in hole in pulley. a. Torque screw to 88.0 Nm (65 ft. lbs.). b. Remove flywheel holder. Fig. 21 – Installing Crankshaft Pulley 9. Install oil pick-up tube and strainer with new gasket. Torque to 8.0 Nm (70 in. lbs.). a. Apply a small bead of Permatex No. 2 or similar sealant to crankcase areas shown, Fig. 22. b.
4 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 4 Flywheel and Rear Seal Retainer Section Contents Page REMOVING OIL PAN AND FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVING REAR SEAL RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REPLACING OIL SEAL . . . . . . . . . . . . .
4 FLYWHEEL AND REAR SEAL RETAINER REMOVE REAR SEAL RETAINER Remove rear seal retainer and discard gasket, Fig. 3. Fig. 3 – Removing Seal Retainer REPLACING OIL SEAL 1. Remove oil seal, Fig. 4. Fig. 4 – Removing Oil Seal 2. Lubricate outside diameter of oil seal. a. Using seal driver, Tool #19424 install new oil seal, Fig. 5. Fig. 5 – Installing Oil Seal INSTALLING REAR SEAL RETAINER AND FLYWHEEL 1. Install rear seal retainer with new gasket, Fig. 6. a. Torque screws to 6.0 Nm (50 in. lbs.).
4 FLYWHEEL AND REAR SEAL RETAINER 2. Install flywheel, Fig. 7. NOTE: Apply Permatex No. 2 or similar sealant to flywheel screws. a. Torque flywheel screws to 47.0 Nm (35 ft. lbs.). Remove flywheel holder. Fig. 7 – Installing Flywheel INSTALL OIL PAN 1. Install oil pan with new gasket, Fig. 8. SEALANT a. Apply a small bead of Permatex No. 2 or similar sealant to crankcase areas shown. b. Torque screws and nuts to 8.0 Nm (70 in. lbs.). Fig.
5 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 5 Cylinder Block Disassembly Section Contents Page ENGINE STAND FIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CYLINDER BLOCK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 CYLINDER BLOCK DISASSEMBLY ENGINE STAND An automotive type engine stand is recommended when complete engine disassembly is required. See drawings below for dimensions to make an engine stand mounting fixture. The engine stand shown below is manufactured by Snap-On. 215 mm 65 mm 8-3/8” HOLES 60 mm 80 mm 65 mm 45 mm 45 mm 50 mm 57 mm 39 mm 107 mm Mounting Plate 1/2” THICK THRU HOLE 21/32” 2 THRU HOLES 13/32” 13” 5/8” 1-1/2” 1-1/2” DIA.
5 CYLINDER BLOCK DISASSEMBLY CYLINDER BLOCK DISASSEMBLY 1. Remove cylinder head. See Sec. 2. STARTER MOTOR 2. Remove oil pan, oil pick up tube, timing cover, gears and gear case. See Sec. 3. 3. Remove flywheel and rear seal retainer. See Sec. 4. 4. Remove starter motor, Fig. 1. Fig. 1 – Removing Starter And Bracket 5. Remove alternator bracket and alternator, Fig. 2. ALTERNATOR BRACKET Fig. 2 – Removing Alternator 6. Remove valve lifters, Fig. 3. VALVE LIFTER a.
5 CYLINDER BLOCK DISASSEMBLY 8. Remove connecting rod and piston assemblies, Fig. 5. NOTE: Remove carbon or ridge from cylinder and number connecting rod/piston assemblies before removing from cylinders. a. Remove connecting rod cap with lower bearing. b. Push connecting rod and piston out through top of cylinder. c. Reassemble connecting rod cap to connecting rod to prevent interchanging components. Fig. 5 – Removing Connecting Rod Assembly 9.
6 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 6 Cylinder Block Inspection and Repair Section Contents Page CHECKING CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REPLACING CAMSHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REPLACING CAMSHAFT PLUG . . .
6 CYLINDER BLOCK INSPECTION AND REPAIR 3. Check cylinder bores for wear, Fig. 3. Standard Bore Size: Model Series 430000 & 520000: 68.00-68.030 mm (2.6770-2.6783”) Model Series 580000: 72.00-72.030 mm (2.8346-2.8358”) a. Measure cylinder bore in 6 points at right angles as shown, Fig. 3. b. If cylinder bore is worn more than 0.075 mm (.003”) or more than 0.035 mm (.0015”) out of round, it must be resized. Always resize to exactly .25 mm (.010”) over standard bore size.
6 CYLINDER BLOCK INSPECTION AND REPAIR 2. Install camshaft bearing, Fig. 7. a. Use camshaft bearing driver, Tool #19422. NOTE: Notch on camshaft bearing must face out. Be sure oil hole in bearing is aligned with oil hole in cylinder block. Fig. 7 – Installing Cam Bearing REPLACING CAMSHAFT PLUG 1. Remove rear camshaft plug, Fig. 8. a. Use a wood dowel or brass rod to prevent damage to camshaft bearing. Fig. 8 – Removing Camshaft Plug 2.
6 CYLINDER BLOCK INSPECTION AND REPAIR 2. Remove timing gear oil nozzle, Fig. 11. OIL NOZZLE Fig. 11 – Removing Oil Nozzle 3. When re-installing oil nozzle, oil hole must be positioned at 45°"angle, pointing towards idler gear, Fig. 12. IDLER GEAR Fig.
7 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 7 Crankshaft, Camshaft and Bearings Section Contents Page CHECKING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHECKING MAIN BEARING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHECKING CONNECTING ROD BEARING CLEARANCES . . . . . . . . . . . . . . . . .
7 CRANKSHAFT, CAMSHAFT AND BEARINGS 3. Check crankshaft timing gear teeth for damaged teeth, Fig. 3. NOTE: See Section 3 for procedure to check crankshaft timing gear for wear. If crankshaft timing gear teeth are damaged or worn, the crankshaft must be replaced. Fig. 3 – Checking Timing Gear CHECKING MAIN BEARING CLEARANCES If main bearings show signs of flaking or scoring, bearings must be replaced.
7 CRANKSHAFT, CAMSHAFT AND BEARINGS CHECKING CONNECTING ROD BEARING CLEARANCES If connecting rod bearings show signs of flaking or scoring, bearings must be replaced. PLASTIGAGE Connecting rod bearings and crankpin journals must be clean and free of oil. 1. With upper bearing assembled to connecting rod, install connecting rod. a. Lay a strip of plastigage lengthwise on journal, Fig. 7. Do not lay plastigage across oil hole in crankpin journal. Fig. 7 – Install Plastigage 2.
7 CRANKSHAFT, CAMSHAFT AND BEARINGS CHECKING CAMSHAFT 1. Measure camshaft lobe height, Fig. 11. If lobes are not to specification, replace the camshaft. Intake and Exhaust: STD: 30.065-30.135 mm (1.184-1.186”) Reject: 29.965 mm (1.18”) Fig. 11 – Checking Camshaft Lobes 2. Measure camshaft journals, Fig. 12. STD: Front – 35.959-35.975 mm (1.4157-1.4163”) Reject: 35.890 mm (1.413”) STD: Center – 35.910-35.955 mm (1.4138-1.4155”) Reject: 35.84 mm (1.411”) STD: Rear – 35.910-35.955 mm (1.4138-1.
8 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 8 Piston, Rings and Connecting Rod Inspection and Assembly Section Contents Page DISASSEMBLE PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHECKING PISTON AND RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY CHECKING PISTON AND RINGS If the cylinder bore is to be resized there is no reason to check the piston as a new oversized piston will be used. If the cylinder is not going to be resized and the piston shows no signs of scoring, the piston should be checked. 1. Check side clearance of ring grooves using NEW rings, Fig. 3. If a 0.12 mm (0.005”) feeler gauge can be inserted, the ring groove is worn. The piston must be replaced. NEW PISTON RING Fig.
8 PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY 2. Check piston pin bearing, Fig. 7. Engine Models: 432447, 522447, 582447 a. Replace if greater than 18.03 mm (0.710”) or .01 mm (.0004”) out of round. Engine Models: 58A447, 588447 b. Replace if greater than 21.03 mm (0.828”) or .01 mm (.0004”) out of round. Fig. 7 – Checking Piston Pin Bearing 3. Check crankpin bearing end of connecting rod for out of round, Fig. 8. a. With bearing inserts removed, assemble connecting rod cap and torque to 36.
8 PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY ASSEMBLE PISTON RINGS TO PISTON ID MARK 1. Install piston rings using ring expander, Tool #19340, Fig. 11. TOP a. Install oil ring coil expander making sure wire is inserted fully into coil. b. Install oil ring. c. Install center compression ring then, top compression ring with ID marks up. ID MARK CENTER WIRE OIL COIL EXPANDER Fig. 11 – Installing Piston Rings 2. Stagger ring end gaps as shown, Fig. 12.
9 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 9 Cylinder Block Assembly Section Contents Page INSTALL CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALL PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL ASSEMBLY Oil Pickup Tube . . . . . . .
9 CYLINDER BLOCK ASSEMBLY 3. Install crankshaft with gear facing front of cylinder block, Fig. 3. Take care not to damage journals or bearings. INSTALL SHIMS #3 MAIN BEARING a. Install crankshaft shims on #3 main bearing web with grooves facing out. b. Lubricate journals with engine oil. Fig. 3 – Installing Crankshaft 4. Install main bearing caps, Fig. 4. Lubricate threads of screws with engine oil. a. Install bearing caps in their respective positions with arrows facing front. b.
9 CYLINDER BLOCK ASSEMBLY Rotate crankshaft so that crankpin is at bottom of stroke. Then, lubricate cylinder walls, piston and rings, bearings and crankpins. 2. Using ring compressor, Tool #19070, install piston and connecting rod assemblies with arrow on piston facing front, Fig. 6. a. Install connecting rod cap with ID mark facing front. Lubricate threads and torque nuts to 34.0 Nm (320 in. lbs.). NOTE: After torquing rod cap, make sure crankshaft rotates freely before proceeding to next cylinder.
9 CYLINDER BLOCK ASSEMBLY INSTALL TIMING GEAR CASE, CAMSHAFT AND GEARS 1. Lubricate oil pump rotor with engine oil and install in cylinder block, Fig. 10. ID MARK a. ID mark on rotor must face cylinder block. OIL PUMP ROTOR Fig. 10 – Installing Oil Pump Rotor 2. Install timing gear case with new gasket. NOTE: It may be necessary to rotate oil pump drive to engage oil pump rotors. Note position, length and number of screws as shown, Fig. 11. a. M6 x 28 mm (M6 x 1.1”): 4 b. M6 x 16 mm (M6 x .
9 CYLINDER BLOCK ASSEMBLY 5. Assemble injector pump to gear case with new O-ring and install nuts and support bracket screw finger tight, Fig. 14. NOTE: Pump must be able to rotate a. Align timing mark on injection pump with timing mark on gear case. NOTE: See Section 10 for injector pump timing procedure. TIMING MARKS Fig. 14 – Install Injector Pump 6. Assemble idler gear shaft with ID mark up, as shown in Fig. 15. ID MARK UP IDLER GEAR SHAFT Fig.
9 CYLINDER BLOCK ASSEMBLY 9. Install timing gear cover with new gasket. Note position, length and number of screws as shown, Fig. 18. a. b. c. d. M6 x 55 mm (M6 x 2.5”): 3 M6 x 45 mm (M6 x 2.1”): 2 M6 x 30 mm (M6 x 1.1”): 9 M6 nut: 2 Torque screws and nuts to 8.0 Nm (70 in. lbs.). B D B C D C C C A A Fig. 18 – Installing Timing Cover 10. Install crankshaft pulley with timing mark at 12 o’clock position (#1 cylinder), Fig. 19.
10 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 10 Fuel System and Related Components Section Contents Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FUEL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INJECTION PUMP TIMING SPECIFICATIONS . . . . . . . . .
10 FUEL SYSTEM COMPONENTS FUEL INJECTION SYSTEM COMPONENTS FUEL RETURN LINE FUEL FILTER FUEL DELIVERY LINE INJECTOR PUMP INJECTOR FUEL RETURN LINE FUEL LINE FUEL TANK 2
10 INJECTOR PUMP TABLE 1 Injection Pump Timing Engine Date Code Before 99010100 Model/Type No. Timing Specification 432447-0150-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0105-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0106-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0107-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0108-E2 0.93 ± .03 mm (.0365” ± .001”) 522447-0109-E2 0.93 ± .03 mm (.0365” ± .001”) 582447-0105-E2 0.93 ± .03 mm (.0365” ± .001”) 582447-0125-E2 0.81 ± .03 mm (.032” ± .
10 INJECTOR PUMP Checking Injector Pump Timing NOTE: Clean areas around fuel lines and injectors to prevent any dirt from entering injector nozzles or delivery valve ports when fuel delivery lines are removed. 1. Remove fuel delivery lines from injector pump and injector nozzles, Fig. 1. Fig. 1 – Removing Fuel Lines 2. Set No. 1 piston at TDC: REFERENCE POINT a. Rotate crankshaft until timing mark on pulley is aligned with reference point on timing cover, Fig. 2. b.
10 INJECTOR PUMP 5. Slowly rotate crankshaft clockwise until timing mark on pulley aligns with reference point on gear case cover (TDC), Fig. 5. Note dial indicator reading. NOTE: Do not rotate crankshaft past TDC. If crankshaft is rotated past TDC rotate crankshaft back to ‘‘0” and repeat procedure. 6. Refer to timing specification tables on page 3 for correct specification by engine model and type or code number. If indicator reading is within specification, injector pump is properly timed.
10 INJECTOR PUMP 3. While observing dial indicator, slowly rotate injector pump away from cylinder head until indicator shows correct specification. Hold injector pump in this position and tighten outside pump mounting nut, Fig. 9. NOTE: Do not rotate pump past specification. If pump is rotated past specification, rotate pump back toward cylinder head and repeat procedure. OUTSIDE MOUNTING NUT Fig. 9 – Adjusting Timing 4.
10 INJECTORS 4. Remove injector nozzles, Fig. 13. a. Discard injector gaskets. NOTE: Handle injectors with extreme care. Do not drop! Always use new fuel return line and injector nozzle gaskets when servicing fuel system. Fig. 13 – Removing Injectors Checking Injectors Fuel injector nozzle testing requires highly specialized equipment and procedures. Consult the Yellow Pages under Engines-Diesel-Fuel Injection Service & Parts for the nearest diesel fuel injection specialist.
10 INJECTORS 3. Check injector for leakage, Fig. 16. Maintain injector pressure at approximately 120 Bar (1707 psi), for about 10 seconds. Make sure there is no leakage from nozzle or retaining nut area. Fig. 16 – Checking Leakage 4. Check spray pattern of nozzle, Fig. 17. Operate tester handle rapidly while observing pattern. Spray pattern should be uniform and centered under nozzle. NOTE: A buzzing or chattering sound should also occur while operating handle.
10 FUEL FILTER Draining Water Collector Change Fuel Filter When warning lamp comes on, drain water collector as follows: 1. Stop engine. 1. Disconnect sensor wire and remove drain plug. Discard O-ring. 2. Place a drain pan under filter and loosen vent plug. 3. Screw new filter on by hand until gasket contacts housing. Then tighten 1/3 turn more. 3. Loosen drain plug approximately 1 turn and drain water from filter until only fuel flows from filter. 4.
10 INJECTOR PUMP IDENTIFICATION IDENTIFICATION CODE 7 : 700 cc 8 : 850 cc 9 : 950 cc NAME PLATE DESTINATION U : USA J : Japan X : Except for USA SERIAL NUMBER IDENTIFICATION CODE TABLE 3 Engine Speed Specification Chart Pump Mfg. Part No. ID Code Model & Type No.
10 ENGINE SPEED ADJUST IDLE SPEED Engine should be at operating temperature before adjusting idle speed. LOCK NUT IDLE SPEED SCREW SPEED CONTROL LEVER Make sure speed control lever contacts idle speed screw with engine at idle. 1. Loosen idle speed screw lock nut and adjust idle speed screw to obtain RPM specified by model and type number shown in chart, Fig. 23. NOTE: Do exceed RPM shown for specific model and type number. a. Torque lock nut to 6.0 Nm (50 in. lbs.). ÏÏ Ï ÏÏ Ï Fig.
11 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 11 Electrical System Section Contents Page ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GLOW PLUG SYSTEM Glow Plug Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove Glow Plugs . . . . . . . . . . . . . . . . . . . . .
11 Section Contents (Continued) Page STARTER SYSTEM – GENERAL INFORMATION STARTER CURRENT DRAW TEST – INSTALLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Electrical System Components (Typical 40 Amp Alternator Shown) FUEL FILTER INJECTION PUMP WATER INDICATOR LIGHT PREHEATING TIMER 1 2 3 KEYSWITCH PART NO.
11 GLOW PLUG SYSTEM Glow Plug The glow plug is a self regulating type, consisting of two metal heating element coils; a rush coil and a brake coil, Fig. 2. The rush coil provides rapid heating of the tip of the glow plug. The brake coil decreases current to the glow plug by increasing resistance as the temperature rises, regulating the temperature of the glow plug. RUSH COIL BRAKE COIL Glow Plug Specifications Rated Voltage Rated Current Normal Resistance 11V 9.5A 1.0 Ω Fig.
11 GLOW PLUG SYSTEM PREHEAT TIMER AND GLOW RELAY The preheat timer and glow relay regulate current to the glow plugs for preheating and starting. When the keyswitch is turned to the “On” position, with the engine cold, the preheat timer activates the glow plugs. An indicator light lights and remains on while the glow plugs are preheating the combustion chamber. When the indicator light goes out, the engine may be started.
11 GLOW PLUG SYSTEM KEYSWITCHES 2+5 ON Two types of keyswitches may be used on Briggs & Stratton Daihatsu diesel engines. 1+3+6 START OFF 2 + 4 +5 NOT USED Fixed Timer Preheat Keyswitch – Part No. 493625 START ON Keyswitch, Part No. 493625, is used with a preheat timer and glow relay, Fig. 8. With the keyswitch in the “On” and “Start” position, battery current is supplied to the preheat timer and glow relay. See keyswitch terminal positions and functions, Fig. 8. 3 2 3 2 4 5 1 See Fig.
11 CHARGING SYSTEMS 14 AMP CHARGING SYSTEM The 14 amp charging system consists of two components: 1. The belt driven permanent magnet alternator produces AC voltage, Fig. 11. AC output will vary with engine RPM, from approximately 7 volts AC at 1000 RPM to 32 volts AC at 3000 RPM. NOTE: A loose V-belt will cause low AC output. Belt deflection limit is 9.5-11.5 mm/10 kg. (3/8-7/16 in./22 lb.). Fig. 11 – 14 Amp Alternator 2.
11 CHARGING SYSTEMS Testing Alternator – AC Output The alternator output test will be performed with the meter in the V~ (AC volts) position, Fig. 14. Disconnect alternator wires at connector. Attach meter test leads to alternator output connectors BEFORE starting engine, Fig. 14. 1. With the engine running at 3300 RPM the output should be no less than 28 volts AC. a. If no output or low output is found, replace alternator. b.
11 CHARGING SYSTEMS Charging Indicator Circuit The green wire from the regulator-rectifier is used to activate the charging indicator light. With the keyswitch in the “ON” position and the engine not running the charge indicator light should light, Fig. 16. With the engine running the light should go out, indicating that the battery is being charged. If the charge indicator light does not light when the keyswitch is in the “ON” position (engine not running), check the bulb and wiring.
11 CHARGING SYSTEMS 40 AMP CHARGING SYSTEM “L” TERMINAL Fig. 1 shows wiring diagram for 40 amp charging system. The 40 amp charging system consists of a belt driven, internally regulated alternator, Fig. 19. “IG” TERMINAL The alternator contains a charge light circuit (“L” terminal). With the keyswitch in the ON position and the engine not running the charge indicator light should light. With the engine running the light should go out, indicating that the battery is being charged.
11 CHARGING SYSTEMS DISASSEMBLE ALTERNATOR 1. Remove pulley nut using tool #19491 and 10 mm deep socket as shown in Fig. 22. a. Remove pulley and spacer. Replace pulley if damaged or worn. Fig. 22 – Remove Pulley 2. Remove nut and insulator at “B” terminal. 3. Remove three screws and brush cover, Fig. 23. B TERMINAL Fig. 23 – Remove Rear Cover 4. Remove two screws, assembly, Fig. 24. then brush retainer Important: Length of brush retainer screws are different. Do not mix. Screw “A”: 11.
11 CHARGING SYSTEMS 6. Remove four stator lead screws from rectifier, Fig. 26. a. Carefully straighten stator leads. b. Remove rectifier. STATOR LEADS STATOR LEADS Fig. 26 – Remove Rectifier 7. Scribe or place a reference mark on drive end and brush end housing so that they may be re-assembled in original position. 8. Remove two nuts and two thru bolts. 9. Remove brush end housing being careful not to damage stator leads, Fig. 27. Fig. 27 – Remove Brush End Housing 10.
11 CHARGING SYSTEMS INSTALL BALL BEARING 1. Lightly lubricate bearing O.D. with engine oil. 19226 DRIVER 2. Press in new bearing using bearing driver #19226, Fig. 30. 3. Install retainer and four screws. Fig. 30 – Install Ball Bearing CHECKING ROTOR The following test will be made with the meter in the 1 “Diode Test Position” . 1. Use digital multimeter and check for continuity between slip rings as shown, Fig. 31. 2 a. Meter should make continuous tone (continuity). b.
11 CHARGING SYSTEMS CHECK REGULATOR B The following test will be made with the meter in the “Diode Test Position” . 1. Attach BLACK meter test lead to terminal “A” as shown, Fig. 34. 2. Contact terminal “B” with RED meter test lead, Fig. 34. a. Meter should “beep” once. b. If meter displays “OL” or makes a continuous tone, regulator is defective. Replace regulator. A Fig. 34 – Check Regulator CHECK RECTIFIER The following test will be made with the meter in the “Diode Test Position” . 1.
11 CHARGING SYSTEMS 3. Assemble brush end housing to drive end housing with reference marks aligned, Fig. 38. Note: Do not damage stator leads. 4. Install thru bolts and nuts. a. Torque to 5.0 Nm (45 in. lbs.). Fig. 38 – Assemble Housings 5. Align stator wires with holes in rectifier and assemble rectifier to brush end housing, Fig. 39. 6. Carefully form a “U” bend in stator wires. a. Install screws and tighten securely. RECTIFIER Fig. 39 – Install Rectifier 7.
11 CHARGING SYSTEMS 9. Install brush holder. Important: Length of brush retainer screws are different. Install as shown, Fig. 42. Screw “A”: 11.5 mm Screw “B”: 9.0 mm B 9.0 mm A 11.5 mm Fig. 42 – Install Brush Holder 10. Install rear cover and three screws, Fig. 43. a. Torque screws to 3.0 Nm (25 in. lbs.). 11. Install insulator and nut. a. Torque nut to 4.0 Nm (35 in. lbs.). Fig. 43 – Install Cover Torque drive pulley using the following procedure, Fig. 44. 1. Hold nut with tool #19491.
11 STARTER SYSTEM IDENTIFICATION NUMBER 28100-87805 Fig. 45 – 1.0 Kw (Standard) IDENTIFICATION NUMBER 28100-87806 Fig. 46 – 1.2 Kw (Optional) STARTER SYSTEM – GENERAL INFORMATION Two different starter motors are used on Briggs & Stratton Daihatsu diesel engines. The standard motor is rated at 1.0 Kw., Fig. 45. The optional starter is rated at 1.2 Kw., Fig. 46. The starters are identified by their identification numbers.
11 STARTER SYSTEM Testing Starter – All NOTE: To prevent engine from starting, remove fuel shut off solenoid wire from injector pump. NEGATIVE BATTERY CABLE RED LEAD The starter current draw test will be performed with the meter in the BLACK LEAD position. The DC Shunt must be installed on the negative (-) terminal of the battery, Fig. 48. 1. Attach RED meter test lead to RED post terminal on shunt. 2. Attach BLACK meter test lead to BLACK post terminal on shunt. 3. Activate starter. a.
11 . STARTER SYSTEM STARTER SOLENOID Test Equipment The starter solenoid test is performed with the starter removed from the engine. BATTERY CABLE The following equipment is recommended to test the solenoid. 1. One battery cable with alligator clips. Fig. 50. 2. A jumper wire. JUMPER WIRE 3. A fully charged 12 volt battery. Fig. 50 – Test Equipment Testing Starter Solenoid 1. Attach one end of battery cable to negative battery terminal and other end of cable to a good ground such as drive housing.
11 STARTER SYSTEM Remove Solenoid 1. Remove nut and field coil wire from stud terminal on solenoid, Fig. 52. FIELD COIL WIRE Fig. 52 – Removing Field Coil Wire 2. Remove through bolts and starter motor, Fig. 53. DO NOT remove armature from starter housing or it will be necessary to re-assemble brushes to armature. Fig. 53 – Removing Starter Motor 3. Remove two drive end cap screws. Hold starter in vertical position with drive housing down and separate solenoid housing from drive housing, Fig. 54.
11 STARTER SYSTEM Check Pinion And Clutch Assembly Check pinion and gear for damage, Fig. 56. Pinion and shaft must rotate in clutch in clockwise direction only. Bearings must turn freely. CLOCKWISE NOTE: The pinion and clutch must be replaced as an assembly. Fig. 56 – Checking Pinion And Clutch Assemble Pinion And Clutch Assembly B 1. Lubricate the following components with silicone grease before assembly, Fig. 57. NOTE: See insert for correct assembly for type starter. a. Clutch gear. b.
11 STARTER SYSTEM Install Solenoid 1. Insert return spring into solenoid plunger. 2. Align pilot hole in solenoid with drive gear shaft and assemble solenoid to drive housing, Fig. 60. a. Torque screws to 9.0 Nm (80 in. lbs.). DRIVE HOUSING DOWN Fig. 60 – Installing Solenoid 3. Assemble starter motor to drive housing. Align tab on starter with notch in drive housing, Fig. 61. a. Torque screws to 9.0 Nm (80 in. lbs.). 4. Install field coil wire. a. Torque nut to 8 Nm (70 in. lbs.). Fig.
11 STARTER SYSTEM 5. Remove two nuts with 14 mm wrench, Fig. 64. 6. Remove components in sequence shown, Fig. 65. Field Wire Terminal Side: (1) G (2) F (3) E (4) D (5) C (6) B (7) A Fig. 64 – Loosen Nuts Battery Wire Terminal Side: Before 99010100: 1.0 KW / After 98123100: 1.0 KW Before 98083100: 1.2 KW / After 98090100: 1.2 KW (1) N (1) N (2) M (2) M (3) L (3) P (4) K (4) O (5) J (5) K (6) I (6) J (7) H (7) I BEFORE 99010100: 1.0 KW / BEFORE 98083100: 1.2 KW H I (1.2 KW) J N (1.
11 STARTER SYSTEM 9. Install new plunger and spring. 10. Place bearing driver, Tool #19422 on plunger and compress plunger to end of travel. Maintain pressure. a. Torque nuts to 17 Nm (150 in. lbs.). Note: This provides proper contact alignment with plunger and contact plates. 11. Clean contact plates and plunger contacts. 12. Install cover plate with new gasket. a. Torque screws to 4 Nm (35 in. lbs.). Fig. 66 – Aligning Contact Plates DISASSEMBLE STARTER MOTOR 1. Remove starter motor from drive housing.
11 STARTER SYSTEM Use digital multimeter and check for continuity between field coil wire and brushes shown, Fig. 70. The following test will be made with the meter in the “Diode Test Position” . 1. Attach either meter test lead to field coil wire. 2. Contact first one positive brush, then opposite brush with other test lead as shown. a. Meter should make continuous tone (continuity). b. If meter does not make a tone, (no continuity) replace starter housing. Fig. 70 – Checking Brushes 3.
11 STARTER SYSTEM ASSEMBLE STARTER MOTOR For ease of assembly, clamp splined end of armature in a vise as shown. Use soft jaws to prevent damage to spline, Fig. 74. 1. Place green seal protector from Kit #19356 over commutator. Fig. 74 – Assemble Starter Motor 2. Using seal protector as a guide, slide motor housing with brush retainer into position, Fig. 75. Remove seal protector. a. Make sure brush wires are not grounding on brush retainer. Fig. 75 – Assembling Motor Housing And Brushes 3.
11 STARTER SYSTEM Wiring Diagram – 14 Amp Alternator (Typical) 493625 Keyswitch With Fixed Preheat Timer and Glow Relay INJECTION PUMP FUEL FILTER PREHEATING TIMER WATER INDICATOR LIGHT 1 2 3 4 6 KEYSWITCH PART NO.
11 STARTER SYSTEM Wiring Diagram – 40 Amp Alternator (Typical) 493625 Keyswitch With Fixed Preheat Timer and Glow Relay FUEL FILTER INJECTION PUMP WATER INDICATOR LIGHT PREHEATING TIMER 1 2 3 KEYSWITCH PART NO.
11 STARTER SYSTEM Wiring Diagram – 14 Amp Alternator (Typical) 825129 Keyswitch – Manual Preheat INJECTION PUMP FUEL FILTER WATER INDICATOR LIGHT KEYSWITCH PART NO. 825129 B G1 S G2 B M GLOW LIGHT KEYSWITCH TERMINAL FUNCTION B BATTERY S SOLENOID GLOW PLUGS SOLENOID CHARGE INDICATOR LIGHT G1 GLOW PLUG (PREHEAT) G2 GLOW PLUG (CRANKING) M ACCESSORY YELLOW GREEN STARTER MOTOR RED REGULATOR RECTIFIER BLACK LT.
11 STARTER SYSTEM Wiring Diagram – 40 Amp Alternator (Typical) 825129 Keyswitch – Manual Preheat FUEL FILTER INJECTION PUMP WATER INDICATOR LIGHT KEYSWITCH PART NO. 825129 B G1 S G2 B M GLOW LIGHT SOLENOID GLOW PLUGS KEYSWITCH TERMINAL FUNCTION B BATTERY S SOLENOID G1 GLOW PLUG (PREHEAT) G2 GLOW PLUG (CRANKING) M CHARGE INDICATOR LIGHT “IG” TERMINAL “L” TERMINAL STARTER MOTOR ACCESSORY “B” TERMINAL 40 AMP ALTERNATOR “B” TERMINAL 12 VOLT BATTERY “IG” TERMINAL “L” TERMINAL Fig.
12 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 12 Lubrication System Section Contents Page DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHANGE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 LUBRICATION SYSTEM DESCRIPTION Briggs & Stratton Daihatsu gasoline and diesel engines use a full pressure lubrication system with an oil filter. The gear driven oil pump draws oil from a screened oil pickup in the oil pan and pumps the oil through the oil filter. The filtered oil flows through oil galleries in the cylinder block and is distributed to the main bearings, connecting rod bearings, camshaft bearings and rocker arm shaft. A pressure relief valve limits the maximum oil pressure in the system.
12 LUBRICATION SYSTEM CHECK OIL PRESSURE 1. Oil level should be between the LOW and FULL marks on dipstick. If oil level is low, check for leaks and add to FULL mark. OIL LEVEL SHOULD BE BETWEEN F AND L MARKS ON DIPSTICK. Fig. 4 – Oil Level 2. Remove oil pressure switch. 3. Install oil pressure gauge. 4. Start the engine and allow it to reach normal operating temperature. 5. Check oil pressure at 3000 RPM. Oil Pressure: 2.0 ~ 5.0 Bar (28 ~ 70 psi) See charts below for troubleshooting guide.
12 LUBRICATION SYSTEM Exploded View DISASSEMBLE GEAR CASE Remove Oil Pump Make sure that #1 cylinder is at TDC, compression stroke. See Section 2. Remove V-belt and fan (if equipped). Drain oil from engine. NOTE: Clean areas around fuel lines and injectors to prevent dirt entry. 1. Remove the following parts, Fig. 6. a. Glow plug wiring. b. Glow plugs. c. Injector pump bracket. d. Remove fuel delivery lines. 4 D B A C Fig.
12 LUBRICATION SYSTEM 2. Remove oil pan screws and nuts. a. Remove oil pan and discard gasket. b. Remove oil pick-up tube and strainer. Discard gasket, Fig. 7. OIL PICK-UP TUBE Fig. 7 – Removing Oil Pan 3. Remove bell housing adapter screw if equipped. and install flywheel holder, Tool #19418. LEAVE TOOL INSTALLED. a. Remove crankshaft pulley using Tool # 19420, Fig. 8. FLYWHEEL HOLDER Fig. 8 – Removing Crankshaft Pulley 4. Remove timing gear cover, Fig. 9. a. Discard timing gear cover gasket. Fig.
12 LUBRICATION SYSTEM 6. Remove injector pump timing gear with a three jaw puller, Fig. 11. a. Remove 2 nuts and injector pump. Discard O-ring. O–RING Fig. 11 – Removing Injector Pump 7. Remove parts in sequence shown, Fig. 12. a. Remove 3 screws and camshaft retainer. b. Remove remaining 5 screws. c. Remove timing gear case and discard gasket. A B B Fig. 12 – Removing Timing Gear Case 8. Inspect rotors for wear or damage, Fig. 13. NOTE: If pump rotors are worn or damaged, replace the gear case.
12 LUBRICATION SYSTEM ASSEMBLE GEAR CASE Install Oil Pump 1. Lubricate oil pump rotor with engine oil and install in cylinder block, Fig. 15. a. ID mark on rotor must face cylinder block. ID MARK OIL PUMP ROTOR Fig. 15 – Installing Oil Pump Rotor 2. Install timing gear case with new gasket. Install camshaft retainer, Fig. 16. NOTE: It may be necessary to rotate oil pump drive to engage oil pump rotors. NOTE: Position camshaft retainer so that center hole does not interfere with camshaft.
12 LUBRICATION SYSTEM 6. Torque screws as shown, Fig. 19. a. Camshaft gear: 41.0 Nm (30 ft. lbs.) b. Idler gear: 25.0 Nm (220 in. lbs.) c. Injector pump gear: 61.0 Nm (45 ft. lbs.) d. Oil pump gear: 19.0 Nm (170 in. lbs.) C A B D Fig. 19 – Torque Screws 7. Install timing gear cover with new gasket. Note position, length and number of screws as shown, Fig. 20. a. M6 x 55 mm (M6 x 2.5”): 3 b. M6 x 45 mm (M6 x 2.1”): 2 c. M6 x 30 mm (M6 x 1.1”): 9 d. M6 nut: 2 8. Torque screws and nuts to 8.0 Nm (70 in.
12 LUBRICATION SYSTEM 11. Install Glow plugs, wiring and fuel delivery lines. a. Torque glow plugs to 17.0 Nm (150 in. lbs.). b. Torque fuel delivery lines to 25.0 Nm (220 in. lbs.), Fig. 23. Fig. 23 – Installing Fuel Delivery Lines 12. Install V-belt, Fig. 24. 13. Install alternator bolts A and B . Belt deflection limit is 10–12 mm/10 kg (3/8–1/2 in/22 lbs.). A a. Torque bolt A to 19.0 Nm (170 in. lbs.). b. Torque bolt B to 61.0 Nm (45 ft. lbs.). 3/8 – 1/2 Inch (10 – 12 mm) BELT MOVEMENT B Fig.
13 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 13 Cooling System Section Contents Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHECKING COOLING SYSTEM Pressure Testing Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Testing Radiator Cap . . . . . . . . . . . . . . . . .
13 COOLING SYSTEM CHECKING COOLING SYSTEM WARNING: The cooling system is pressurized. Do not remove the radiator cap while the engine is hot. To avoid scalding hot coolant or steam blowing out of the radiator, use extreme care when removing the radiator cap. If possible, wait for engine to cool. Wrap a thick rag around cap while removing. To release pressure, slowly turn cap counter clockwise to the first stop. When all pressure has been released, press down on cap and continue turning.
13 COOLING SYSTEM THERMOSTAT COOLANT OUTLET Removing Thermostat – Engine Cold 1. 2. 3. 4. THERMOSTAT Drain engine coolant. Remove screws and coolant outlet housing. Remove locating screw and thermostat, Fig. 3. Remove all traces of gasket material. LOCATING SCREW Fig. 3 – Removing Thermostat Checking Thermostat A thermometer capable of reading 100° C (210° F) or more is required. 1. Check to make sure thermostat valve is fully closed. 2. Immerse thermostat in water and heat water gradually, Fig. 4.
13 COOLING SYSTEM WATER PUMP VENT HOLES Inspecting Water Pump Inspect water pump for signs of leaking at vent holes, mounting surfaces and water pump pulley shaft, Fig. 6. 1. Remove V-belt, alternator adjustment bracket, fan (if equipped) and water pump pulley. a. Replace pulley if bent or damaged. Fig. 6 – Inspecting Water Pump 2. Check water pump bearings by rotating pulley flange by hand, Fig. 7. a. Make sure pulley rotates smoothly.
13 COOLING SYSTEM Installing Water Pump 1. Install water pump with new gasket, Fig. 10. a. Torque screws and nuts to 19.0 Nm (170 in. lbs.). After installing water pump make sure pump rotates smoothly. Fig. 10 – Installing Water Pump 2. Install coolant inlet with new gasket, Fig. 11. a. Torque screws to 8.0 Nm (70 in. lbs.). 3. Install thermostat and coolant outlet with new gasket, Fig. 11. a. Torque screws to 8.0 Nm (70 in. lbs.). 4. Install temperature gauge wire (if equipped). 5.
14 BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section 14 Turbocharger Section Contents Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Turbocharger Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Turbocharger Cooling System . . . . . . . . .
14 950 CC DIESEL TURBOCHARGED ENGINE General Information Models 588447 and 58A447 are turbocharged equipped diesel engines. Turbocharger Lubrication System Lubricating oil for the turbocharger is supplied from the rear of the cylinder head to the turbocharger via the oil inlet line. The oil supply is regulated by the inlet port diameter of the oil inlet line. The oil inlet line is installed with union screws at the cylinder head and the turbocharger.
14 TURBOCHARGER Turbocharger Cooling System Coolant for the turbocharger is supplied from the rear right of cylinder block and returns to the water pump inlet. COOLANT OUTLET LINE COOLANT INLET LINE Fig. 3 – Cooling System of Turbocharger (1) COOLING WATER TO WATER PUMP INLET COOLING WATER FROM CYLINDER BLOCK Fig.
14 TURBOCHARGER Turbocharger Waste Gate The turbocharger is equipped with a waste gate to control turbocharger pressure. WASTE GATE VALVE WASTE GATE ACTUATOR Fig. 5 – Turbocharger Turbocharger Pressure Control System As pressure in the turbocharger rises, the actuator for the waste gate valve opens allowing some of the exhaust gases to bypass the turbocharger.
14 TURBOCHARGER Crankcase Blow-by Recirculating System Crankcase blow-by is recirculated as shown in Fig. 7 CRANKCASE BREATHER TUBE A/C IN FRESH AIR EX BLOW-BY GASES T/C EXHAUST GASES Fig. 7 – Crankcase Blow-by Recirculating System CHECKING WASTE GATE ACTUATOR 1. Disconnect the waste gate actuator hose at the actuator. 2. Connect pressure/vacuum pump, Tool #19493. 3. Apply pressure of 14.2 psi (0.9 bar) and ensure that the rod and link operate. 4.
14 TURBOCHARGER SERVICING AND OPERATION INFORMATION 1. DO NOT disassemble the turbocharger. 2. When removing and installing turbocharger: a. Handle the turbocharger carefully. DO NOT drop. b. When removing the air intake system or lubrication system, be careful not to get dust or foreign matter into the turbocharger. c. Use tape to cover the oil inlet and outlet ports, coolant ports, air intake and exhaust port to prevent the turbocharger from getting dust or debris into it. d.
14 TURBOCHARGER REMOVE TURBOCHARGER 1. Remove the muffler or exhaust pipe from the turbocharger. 2. Lift tab on tie strap and remove tie strap. Then remove crankcase breather tube at air intake tube. TIE STRAP TAB Fig. 13 – Remove Clamp 3. Disconnect the air intake tube at the turbocharger. 4. Disconnect the air intake tube from the air intake pipe. AIR INTAKE TUBE Fig. 14 – Disconnecting Air Intake Tube 5. Remove the two nuts, and remove the air intake pipe from turbocharger. AIR INTAKE PIPE Fig.
14 TURBOCHARGER 7. Remove coolant outlet hose. OUTLET HOSE Fig. 17 – Disconnect Coolant Hose 8. Remove coolant inlet line bracket screw. BRACKET Fig. 18 – Remove Clamp 9. Remove two nuts, then remove coolant line assembly from turbocharger . Fig. 19 – Removing Coolant Line 10. Remove oil inlet line union screw at turbocharger. Discard the washer. Fig.
14 TURBOCHARGER 11. Remove oil inlet line union screw at rear of cylinder head. Discard washers. Fig. 21 – Removing Union Screw 12. Remove oil inlet line bracket screw at the exhaust manifold. Fig. 22 – Removing Bracket Bolt 13. Remove two screws from turbocharger and pull out the oil outlet tube from the cylinder block. Discard “O” ring and gasket. Fig. 23 – Removing Oil Outlet Tube 14. Remove screws (2) and nuts (3) and remove turbocharger mounting bracket. Discard gasket. Fig.
14 TURBOCHARGER 15. Remove nuts (3), and remove the turbocharger assembly from the exhaust manifold. Fig. 25 – Removing Turbocharger Assembly NOTE: When removing the turbocharger assembly, DO NOT lift or carry turbocharger by the waste gate actuator rod. Use tape to cover the oil inlet and outlet ports, coolant ports, air intake and exhaust port. Fig. 26 – Removing Turbocharger Assembly CHECKING TURBOCHARGER 1. Check blades of turbine and compressor for damage. 2.
14 TURBOCHARGER INSTALL TURBOCHARGER 1. Install the turbocharger assembly with new gasket. a. Torque nuts (3) to 25 Nm (18.0 ft.-lb). Fig. 29 – Installing Turbocharger Assembly 2. Install the turbocharger bracket with new gasket. a. Temporarily tighten the nuts and bolts until the flange surfaces of the turbocharger, exhaust manifold and turbocharger stay in contact each other. b. First torque nuts to 34.0 Nm (25.0 ft.-lb) c. Then torque screws to 29.0 Nm (20.0 ft.-lb) Fig.
14 TURBOCHARGER 4. Install oil inlet line. a. Temporarily install the union screw with washers at the cylinder head. b. Temporarily install the union screw with washer at the turbocharger. c. Temporarily install the inlet line bracket screw. d. Then torque union screws and bracket screw. Union screws: Cylinder head side – Turbocharger side – 44.0 Nm 18.0 Nm (170 in-lb) (32.0 ft.-lb) Fig. 32 – Installing Oil Inlet Line Bracket screw: 19.0 Nm (170. in-lb) Fig. 33 – Installing Bracket Screw 5.
14 TURBOCHARGER 7. Install coolant outlet hose from turbocharger to coolant inlet housing as shown, Fig. 36. Install clamps with tabs as shown. Fig. 36 – Install Coolant Outlet Hose 8. Install coolant inlet hose over inlet tube up to yellow mark on tube. Install clamps with tabs as shown. B A YELLOW MARK Fig. 37 – Install Coolant Inlet Hose 9. Install air intake pipe. a. Torque nuts to 13.0 Nm (115 in. lbs.). AIR INTAKE PIPE Fig. 38 – Installing Air Intake Pipe 10.
14 TURBOCHARGER 11. Install breather tube as shown. 12. Install muffler or exhaust pipe. 13. Connect the air hose connecting the air cleaner to the turbocharger. PIPE PULL BREATHER TUBE Fig. 40 – Installing Clamp INSTALLATION OF COOLANT INLET TUBE 1. Apply sealer to the portion of tube that is to be installed in cylinder block. 2. Align the center of tube with the center of M10 thread at the rear end of the cylinder block. 3. Press-in tube until flange contacts the cylinder block.
REPAIR MANUAL For 3 Cylinder LiquidĆCooled Diesel Engines FORM MS-1055-5/02 2002 BRIGGS & STRATTON DAIHATSU LLC PRINTED IN U.S.A.
