NISSAN BD30T ENGINE SERVICE MANUAL [ EXCAVATOR ] by engineparts2

SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS INSPECTION AND ADJUSTMENT

INJECTION AND FUEL SYSTEM

BASIC MECHANICAL SYSTEM

Injection timing T027

Valve clearance (Hot) Intake & Exhaust

mm Onl

Fan belt deflection mm On)/98 N (10 kg, 221b) Used ... New

(0.43 - 0.51)

9 - 11 (0.35 - 0.43)

Engine oil capacity (Without oil filter) T027

(US qt, Imp qt)

6° /700

Idling

rpm

700

Max. engine speed under no-load

rpm

2,600 - 2,700

Initial injection pressure kPa (bar, kg/cm',

psi) 9,807 (98.1, 100, 1,422)

T027 5.5 (5-7/8, 4.7/8)

B030 Water capacitY T027

B030

0.35 (0.014)

11.13

B.T.O.C./rpm

15,691 (156.9,160,2,275)

B030

7.5 (7-718,6.5/8) (US gal, Imp gal)

B030

10.8 (2-7/8,2.3/8) 11.3 (3, 2-1/2)

TIGHTENING

Radiator cap relief pressure kPa (bar, kg/cm' ,psi)

88 (0.88, 0.9,13)

Cooling system leaking testing pressure kPa (bar, kg/cm' , psi)

147 (1.47,1.5,21)

Cylinder head bolt* 1st step 2nd step

Compression pressure kPa (bar, kg/cm' , psi)/rpm Standard

TORQUE

2,942 (29.4, 30, 427)/200

Intake manifold T027

Minimum Difference between cylinders

kg-m

39 - 44

4.0 - 4.5

29 - 33

54-59

5.5-6.0

40-43

ft-lb

13.19

1.3 - 1.9

9 - 14

14 - 18

1.4 - 1.8

10 - 13

Exhaust manifold

25 -29

2.5 - 3.0

18 - 22

Oil drain plug

49 - 59

5.0 - 6.0

36 - 43

B030 2,452 (24.5, 25, 356)/200

N.m

294 (2.9, 3,43)/200 *: Then turn further 80°

ET-2

100°.

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment Valve guide

COMPRESSION PRESSURE Unit:

Unit:

kPIl (bar, kg/em', psi)/rpm

Standard

2,942 (29.4,30,427)/200

Minimum

2,452 (24.5, 25, 356)/200

Standard

Valve guide outside diameter Differential limit between cylinders

CYLINDER

294 (2.9, 3, 43)/200

HEAD

Unit:

mm (in)

Limit Head surface distortion Nominal cylinder head height

Cylinder head valve guide hole diameter

0.2 (0.008) 89.7 (3.531)

VALVE

Unit:

Valve guide inner diameter (Finished size)

Interference fit of valve guide

Service

12.033 â&#x20AC;˘ 12.044 (0.4737. 0.4742) 8.000 - 8.015 (0.3150 - 0.3156) 12.00 - 12.011 (0.4724 0.4729) 0.022.0.044 (0.0009 - 0.0017) Standard

Max. tolerance

Intake

0.02.0.05 (0.0008 0.0020)

0.15 (0.0059)

Exhaust

0.04.0.07 (0.0016. 0.0028)

0.20 (0.0079)

mm (in)

T (Margin thickness)

mm (in)

Stem to guide clearance

Valve deflection Iim it Intake

0.30 (0.0118)

- L SEM188

Exhaust

0.40 (0.0157)

Valve spring

Valve head diameter "0" Intake

43.5 (1.713)

Free length

Exhaust

38.0 (1.496)

Assembled height mm/N (mm/kg, in/lb)

Valve length "L" Intake

Out of square 117(4.61)

Exhaust Valve stem diameter "d" Intake

8.0 (0.315)

Exhaust

8.0 (0.315)

Valve seat angle "0/' Intake 45Â° Exhaust Valve margin "T" limit

1.0 (0.039)

Valve stem end surface grinding limit

0.2 (0.008)

Valve clearance (Hot) Intake 0.35 (0.0138) Exhaust

EM-2

mm (in)

46.8 (1.843) 42.3/123.6 - 330.5 (42.3/12.6 - 33.7, 1.665/27.8 - 74.3) 2.0 (0.079)

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd) VALVE

LIFTER

AND PUSH ROD

CYLINDER Unit:

Standard

Valve lifter outer diameter

24.960. 24.970 (0.9827 0.9831)

Cylinder block valve lifter hole diameter

25.000 â&#x20AC;¢ 25.033 (0.9843 0.9855)

Valve Iifter to lifter hole clearance

Push rod bend (T.I.R.)*

0.030.0.073 (0.0012. 0.0029) Lessthan 0.3 (0.012)

HEAD TO VALVE

DISTANCE

mm (in)

Unit:

mm (in)

Limit

0.20 (0.0079)

SEM724C

0.5 (0.020) Standard

Limit

*: Total indicator reading Intake

Rocker shaft and rocker arm

--------

Unit: Standard

mm (in)

Outer diameter

T027

0.06 (0.0024)

0.10 (0.00391

B030

0-0.3 (0.0.0121

0.60 (0.0236)

20.02 . 20.04 (0.7882 0.7890)

Rocker arm

Clearance between rocker arm and rocker shaft T027

B030

0.02.0.06 (0.0008. 0.0024) 0.014 - 0.056 (0.0006 0.0022)

B030

0.725 - 1.225 (0.0285 0.0482)

1.25 (0.0492)

Exhaust

Rocker shaft bend (T.I.R.I

Inner diameter

0.225 - 0.725 (0.0089. 0.0285)

Limit

Rocker shaft

19.979 - 20.00 (0.7866 0.7874)

T027

0.20 (0.0079)

0.15 (0.0059)

EM-3

T027

0.255 - 0.745 (0.0100. 0.0293)

B030

0.755 - 1.245 (0.0297. 0.0490)

1.75 (0.0689)

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd) Valve seat

CAMSHAFT Unit:

mm (in)

AND CAMSHAFT

------

BEARING Unit:

mm (in)

Standard

Limit

0.020 • 0.109 10.0008 • 0.0043)

0.15 10.0059)

Front

50.721 .50.740 0.9969 - 1.9976l

2nd

50.521 • 50.540 11.9890. 1.9898)

3rd

50.321 - 50.340 11.9811 . 1.9819)

4th'

50.121 - 50,140 11.9733-1.9740)

Rear

49.921 - 49.940 11.9654 - 1.9661)

Camshaft journal to bushing clearance [Oil clearance]

Camshaft journal diameter

SEM953C

Intake 44.535 -44.545 (1.7533-1.7537)

Outer diameter "0, "

Inner diameter "D2

37.9.38.1 11.492 . 1.500)

Diameter of seat "D3

Camshaft bend (Total indicator reading)

42.4 -42.6 (1.669-1.677)

Cylinder head valve seat diameter

44.500-44.515 11.7520 • 1.7526)

Valve seat face angle "</>"

89° . 91°

Camshaft end play

Less than 0.0210.0008) 0.08 -0.28 10.0031 - 0.0110)

0.06 10.0024)

0.5010.0197l

Exhaust Outer diameter "0, " Standard

39.535 • 39.545 (1.5565 • 1.5569)

0.210.008) Oversize IService)

39.735-39.745 (1.5644-1.5648)

0.4 10.016) Oversize IService)

39.935 • 39.945 11.5722 • 1.5726)

Inner diameter "D2

32.9 - 33.1 (1.295 . 1.303)

Diameter of seat "D3

EM671

Cylinder head valve seat diameter 39.495-39.510 11.5549-1.5555)

0.2 10.008) Oversize

39.695-39.710 11.5628- 1.5634)

0.4 10.016) Oversize

39.895-39.910 11.5707 -1.5713)

Valve seat face angle "</>"

Limit

Intake

41.88 - 41 .92 11.6488 - 1.6504)

41.4 (1.630)

Exhaust

41.88 - 41.92 (1.6488. 1.6504)

41.4 11.630)

Cam height "A"

36.90-37.10 11.4528 . 1.4606)

Standard

89° • 90°

Hino engine parts Mitsubishi engine parts Nissan engine parts for heavy equipment Contact: EngineParts@HeavyEquipmentRestorationParts.com

EM-4

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment CYLINDER

BLOCK AND CYLINDER

(Cont' d) Unit:

LINER Unit:

mm (in)

2010.79)

SEM427

SEM950C

Surface flatness (Without cylinder liner) Standard

Lessthan 0.05 (0.0020)

Limit

0.2 (0.008)

Cylinder bore Inner diameter 99.000 - 99.020 (3.8976 - 3.8984)

Standard Cylinder bore (With cylinder liner) Inner diameter Standard Grade No.1

96.000.96.010 13.7795.3.7799)

Grade No.2

96.010 (3.7799

Grade No.3

96.020 . 96.030 (3.7803 - 3.7807)

Wear limit Out-of.round

96.020 3.7803)

0.20 (0.0079)

IX -

Cylinder liner diameter "0" (service) *

Taper (A - B) Projection "S"

Lessthan 0.040 (0.0016) Lessthan 0.040 (0.0016) 0.02.0.09

(0.0008 - 0.0035)

Division of each cylinder "S"

Lessthan 0.05 10.0020)

Interference fit cylinder liner to block

-0.01 to 0.03 (-0.0004 to 0.0012)

EM-5

Before installing in cylinder block

96.050. 96.070 (3.7815 - 3.7823)

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd) PISTON, PISTON RING AND PISTON PIN Available piston

Unit:

mm (in)

SEM778A

B030

T027 Piston skirt diameter "A" Standard Grade No.1

95.940.95.950

(3.7772 - 3.7776)

95.950 - 95.960 (3.7776 - 3.7779)

Grade No.2

95.950.95.960

(3.7776 - 3.7779)

95.960 - 95.970 (3.7779.3.7783)

Grade No. 3*

95.960 - 95.970 (3.7779 - 3.7783)

95.970 - 95.980 (3.7783 - 3.7787)

70 (2.76)

63.5 (2.500)

27.992 - 28.000 (1.1020. 1.1024)

29.997 - 30.005 (1.1810 - 1.1813)

"a" dimension Piston pin hole diameter Piston to cylinder liner clearance

0.05 - 0.07 (0.0020 - 0.0028)

* Grade No.3 piston is not provided as a service part.

Piston pin

Piston ring

--------

Unit: Standard

Limit

Piston pin outer diameter T027

Side clearance

B030

Top

0.06 - 0.10 (0.0024 - 0.0039)

0.50 (0.0197)

2nd

0.04 -0.08 (0.0016 - 0.0031)

0.30 (0.0118)

Oil

0.02 - 0.06 (0.0008 - 0.0024)

0.15 (0.0059)

Piston pin to piston clearance T027 B030 Piston pin to connecting rod clearance Standard

Ring gap Top

2nd

0.30 - 0.45 (0.0118 - 0.0177) 0.30 -0.45 (0.0118 - 0.Q177)

Limit

1.5 (0.059)

Oil (rail ring) T027

0.25 - 0.45 (0.0098 - 0.0177)

B030

0.20 -0.45 (0.0079 - 0.Q177)

Unit:

mm (in)

EM-6

mm (in)

27.993 - 28.000 (1.1021 - 1.1024) 29.993-30.000

(1.1808-1.1811)

-0.008 to 0.007 (-0.0003 to 0.0003) -0.003 to 0.D12 (-0.0001 to 0.0005)

0.025 - 0.045 (0.0010 - 0.0018) 0.15 (0.0059)

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd) CONNECTING

CRANKSHAFT

ROD Unit: T027

Center distance Bend, torsion [per 100 (3.94)] Limit Piston pin bore dia. Side clearance Standard Limit

Unit:

mm (in)

B030

156.975 - 157.025 (6.1801 - 6.1821)

0.05 (0.0020) 28.025 - 28.033 /1.1033 -1.1037)

30.025 - 30.038 (1.1821 -1.1826)

0.10 - 0.22 10.0039 - 0.0087) 0.22 10.0087)

SEM100A

Journal diameter "A"

70.907 - 70.920 (2.7916 - 2.7921)

Pin diameter "B"

56.913 - 56.962 (2.2407 - 2.2426)

Center distance "S" T027

46.00 (1.8110) 51.00/2.0079)

B030

Out-of-round X-V TaperA-B

Qy EM715

Taper of journal and pin "A-B" Standard Limit Out-of-round of journal and pin "X-Y" Standard Limit Crankshaft bend Standard Limit

0.01 10.0004) 0.02 (0.0008)

0- 0.03 (0.0.0012) 0.1010.0039)

Crankshaft end play Standard T027

B030 Limit

EM-7

0.055 - 0.180 10.0022 - 0.0071) 0.055 - 0.14 (0.0022 - 0.0055) 0.40 (0.0157)

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd) AVAILABLE

MAIN BEARING

AVAILABLE

Bearing clearance

Thrust washer undersize Unit:

Main bearing clearance Standard

0.035-0.087

Limit

mm (in)

(0.0014-0.0034)

0.15 (0.0059)

Connecting rod bearing clearance Standard

THRUST WASHER

0.035-0.081

Limit

------

mm (in)

Th rust washer th ickness

Standard Stamped mark A

2.275 -2.325 (0.0896 -0.0915)

2.300 .2.350 (0.0906 -0.0925)

2.325.2.375

10.0915-0.0935)

Oversize 0.20 (0.0079)

2.475-2.525

(0.0974-0.0994)

0.40 (0.0157)

2.675-2.725

(0.1053 .0.1073)

(0.0014-0.0032)

0.15 (0.0059)

Unit:

Main bearing undersize Unit:

mm (in)

Crank journal diameter

MISCELLANEOUS

Standard

70.907-70.920

Undersize 0.25 (0.0098)

70.657 .70.670 (2.7818.2.7823)

0.50 (0.0197)

70.407.70.420

(2.7719.2.7724)

0.75 (0.0295)

70.157.70.170

(2.7621 -2.7626)

1.00 (0.0394)

69.907.69.920

(2.7522 . 2.7528)

Unit: Gear train Backlash of each gear Limit Flywheel Runout (Total indicator reading) TD27 BD30

AVAILABLE

CONNECTING

Front plate Warpage limit

ROD BEARING

Connecting rod bearing undersize

------

Standard

COMPONENTS

(2.7916 . 2.7921)

Unit:

mm (in)

Crank pin journal diameter 56.913-56.926 (2.2407-2.2412)

Undersize 0.25 (0.0098)

56.663 . 56.676 (2.2308-2.2313)

0.50 (0.0197)

56.413 . 56.676 (2.2210- 2.2313)

0.75 (0.0295)

56.163-56.176 (2.2111 -2.2116)

1.00 (0.0394)

55.913-55.926 (2.2013-2.2018)

EM-8

mm (in)

0.07 . 0.11 (0.0028. 0.0043) 0.20 (0.0079)

Lessthan 0.15 (0.0059) Lessthan 0.10 (0.0039)

0.2 (0.008)

SERVICE DATA AND SPECIFICATIONS Tightening Torque ENGINE OUTER PARTS

ENGINE PARTS N'm

kg-m

ft.lb

Unit

N,m

kg-m

ft-Ib

Unit

Manifold nut Intake

Main bearing cap bolt

167. 177

17.0.18.0

123.130

15 - 20

1,5 - 2.0

11 - 14

Connecting rod big end nut

78.83

8.0.8,5

58 - 61

25 29

2.5 -3.0

18 - 22

Crank pulley nut

294 -324

30.33

217 - 239

29-34

3.0 - 3.5

22.25

Flywheel bolt

147.167

15.0-17.0

108 -123

16.21

1.6.2.1

12 - 15

Exhaust Without turbocharger With turbocharger Injection pump nut

20.25

2.0 - 2.5

14 - 18

Timing gear casebolt

Injection pump to bracket bolt

30 - 41

3.1.4.2

22.30

Timing gear casenut

16.21

1.6 - 2.1

12.15

Front end plate bolt

10.13

1.0.1.3

7-9

Injection nozzle to cylinder head

54.64

5.5 -6.5

40 -47

Camshaft gear bolt

44.49

4.5- 5.0

33- 36

0.4-0.6

2.9.4.3

59-69

6.0 -7.0

43 - 51

Camshaft locating plate bolt

4.6

Injection pump drive gear nut

20.25

19 - 26

Injection tube flare nut

2.0 - 2.5

14 - 18

Spill tube with cap nut

29-39

3,0 -4.0

22 - 29

Alternator bracket bolt

30 - 41

3,1 - 4.2

22 -30

Alternator to adjusting bar bolt

16 - 21

1.6 - 2.1

12 - 15

Idler gear shaft bolt

25.35

2.6.3.6

Oil pan bolt

7.9

0.7 -0.9

5.1 - 6.5

Oil pan drain plug

54 59

5.5 -6.0

40-43

Cylinder head bolt

Refer to installation of cylinder head.

Glow plug

15.20

1.5 - 2.0

11 - 14

Rocker shaft bracket bolt

20 - 25

2.0 - 2.5

14 - 18

Rocker arm lock nut

15 -20

1.5 - 2.0

11 - 14

Rocker cover screw

1-2

0.1 -0.2

0.7.1.4

Head Bolt Tightening Sequence

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EM-9

CHECKING COMPRESSION

PRESSURE (On-vehicle service)

1. Warm up engine. 2. Remove glow plate and glow plugs (TD27 engine) or injection pipe and nozzle holder assembly (6030 engine).

~ SEM6188

F it compression gauge adapter to cylinder head. Compression gauge adapter: ~: 15 - 20 N.m (1.5 - 2.0 kg-m, 11 - 14 ft-Ib)

4. Set no fuel injected condition. Disconnect fuel cut solenoid wire. 5. Crank engine, then read gauge indication. Engine compression measurement should be made as quickly as possible. Compression pressure: Unit:

kPa (bar, kg/cm2, psi)/200 rpm

Standard

2,942 (29.4, 30, 427)

Minimum

2,452 (24.5, 25, 356)

Differential

• • •

limit between cylinders

294 (2.9, 3,43)

If cylinder compression in one or more cylinders is low, pour a small quantity of engine oil into cylinders through the glow holes and retest compression. If adding oil helps the compression pressure, chances are that piston rings are worn or damaged. If pressure stays low, valve may be sticking or seating improperly. If cylinder compression in any two adjacent cylinders is low, and if add ing oil does not help the compression, there is leakage past the gasketed surface. Oil and water in combustion chambers can result from this problem.

EM-10

CYLINDER HEAD

!PJ9-11

(0.9-1.1,6.5.8.01

Adjusting screw

I I Rocker cover

Valve cotter

r ,

Lower seat

Cylinder head bolt !PJ: Refer to "CYLINDER

'0''''''''00

HEAD-

(Oo.V.hl". So,,;,,)".

Cylinder head gasket~ Cylinder head

Always replace when disassembled

!PJ

N.m (kg.m, ft.lbl

SEM693C

EM-12

CYLINDER HEAD Removal (On-vehicle service) 1. 2. 3. 4. 5. 6. 7. 8. 9.

Open top panel. Remove rear floor board. Remove battery. Set NO.1 cylinder at T.O.C. on its compression stroke. Drain engine coolant from drain plugs on cylinder block and radiator. Remove air cleaner and/or air duct. Remove alternator adjusting bolt. Disconnect exhaust manifold from front exhaust tube. Disconnect radiator outlet hose and thermostat housing water inlet hose.

10. Remove fuel injection tube assembly and spill tube.

11. Remove injection nozzle holder and top nozzle gasket using deep socket wrench.

12. Remove rocker cover. 13. Remove rocker shaft with rocker arms. 14. Remove push rods.

EM-13

CYLINDER HEAD Removal (On-vehicle service) (Cont'd) 15. Remove cylinder head bolts in numerical order and remove cylinder head. Head warpage or cracking could result from removing in incorrect order.

Loosen in numerical order.

8030

Engine front

SEM697C

Disassembly 1. • • • • •

Remove following parts: Intake manifold Exhaust manifold Thermostat housing Alternator adjusting bar & engine slinger Glow plate and glow plugs (TD27)

Remove valve component parts with Tool.

Remove valve oil seals with Tool.

KV1 01 07900

EM-14

CYLINDER HEAD

Disassembly (Cont'd) 4. Disassemble rocker shaft assembly. a. Remove rocker shaft lock bolt. b. Remove valve rocker and rocker shaft bracket. If It Is difficult to remove rocker shaft bracket, Immerse rocker shaft assembly In 011 of 70°C (158°F)for a few minutes and then remove bracket.

Inspection CYLINDER HEAD DISTORTION Cylinder head distortion: Limit 0.2 mm (0.008 in) If beyond the specified limit, correct with a surface grinder. Cylinder head height should be greater than 89.7 mm (3.531 in) after surface has been ground.

VALVE GUIDE CLEARANCE •

SEM586A

•

Valve guide clearance should be measured parallel with rocker arm. (Generally, a large amount of wear occurs In this direction.) Stem to guide clearance: Limit Intake 0.15 mm (0.0059 In) Exhaust 0.20 mm (0.0079 In) Maximum allowable deflection (Dial Indicator reading) Intake 0.30 mm (0.0118 In) Exhaust 0.40 mm (0.0157 In) To determine the correct replacement part, measure valve stem diameter and valve guide Inner diameter. Valve stem diameter: 8.0 mm (0.315 in) Valve guide inner diameter: 8.000 • 8.015 mm (0.3150 • 0.3156 In)

EM030

EM-15

CYLINDER HEAD

Inspection (Cont'd) 2.

Place new valve seats on dry ice and allow them to cool for five minutes.

WARNING: Do not touch cooled valve seats with bare hands. 3. Heat cylinder head to 80Â°C (176Â°F). 4. Install cooled valve seats on cylinder head with Tool.

5. Stake exhaust valve seat at five places with punch. When staking valve seat, select different places than those staked before.

6. 7. 8.

Cut or grind valve seat using suitable tool at the specified dimensions as shown in S.O.S. After cutting, lap valve seat with a lapping compound. Check contact condition of valve seat.

Hino engine parts Mitsubishi engine parts Nissan engine parts COMBUSTION CHAMBER [TD27] for heavy equipment Check combustion chamber for cracks and other damage. If Contact: EngineParts@HeavyEquipmentRestorationParts.com necessary, replace. REPLACING

COMBUSTION

CHAMBER

[TD27]

Usually combustion chamber should not be removed. 1. Remove combustion chamber so that cylinder head cannot be damaged. SEM633B

Install combustion chamber.

Identification of combustion chambers: Identification mark (on combustion chamber)

Identificat ion mark

SEM599C

EM-17

Outer diameter "D" mm (in)

Engine

37 (1.46)

TD27

CYLINDER HEAD

Inspection (Cont'd) 2.

Place new valve seats on dry ice and allow them to cool for five minutes.

WARNING: Do not touch cooled valve seats with bare hands. 3. Heat cylinder head to 80Â°C (176Â°F). 4. Install cooled valve seats on cylinder head with Tool.

5. Stake exhaust valve seat at five places with punch. When staking valve seat, select different places than those staked before.

6. 7. 8.

Cut or grind valve seat using suitable tool at the specified dimensions as shown in S.O.S. After cutting, lap valve seat with a lapping compound. Check contact condition of valve seat.

COMBUSTION CHAMBER [TD27] Check combustion chamber for cracks and other damage. If necessary, replace. REPLACING

COMBUSTION

CHAMBER

[TD27]

Usually combustion chamber should not be removed. 1. Remove combustion chamber so that cylinder head cannot be damaged. SEM633B

Install combustion chamber.

Identification of combustion chambers: Identification mark (on combustion chamber)

Identificat ion mark

SEM599C

EM-17

Outer diameter "D" mm (in)

Engine

37 (1.46)

TD27

CYLINDER HEAD Inspection (Cont'd) (1) Cool combustion chamber with dry ice for approximately 5 to 10 minutes. WARNING: Do not touch cooled combustion chamber with bare hand.

Knock pin

Combustion chamber

Align

(2) Align combustion chamber knock pin with cylinder head notch, and drive in combustion chamber with a soft hammer. 3. Check amount of protrusion of combustion chamber. Protrusion: Standard -0.05 to 0.10 mm (-0.0020 to 0.0039 in)

SEM634B

VALVE DIMENSIONS Check dimensions in eachvalve. For dimensions, refer to S.O.S. When valve head has been worn down to 1.0 mm (0.039 in) in margin thickness, replace the valve. Grinding allowance tor valve stem tip is 0.2 mm (0.008 in) or less.

T (Margin thickness)

VALVE

SPRING SQUARENESS Out-ot-square "S": Lessthan 2.0 mm (0.079 in)

VALVE SPRING PRESSURE LOAD Refer to S.O.S.

EM113

EM-18

CYLINDER HEAD Inspection (Cont'd) VALVE LIFTER AND PUSH ROD Valve lifter 1. Check valve lifters for excessive wear on the face. 2. Replace with new ones if worn beyond repair. a. Valve lifter end should be smooth. b. Valve lifter to lifter hole clearance: Standard 0.030 - 0.073 mm (0.0012 - 0.0029 in) Limit Lessthan 0.20 mm (0.0079 in) Valve lifter outer diameter "A": 25.960 - 25.970 mm (1.0220 - 1.0224 in) Cylinder block valve lifter hole diameter liB": 26.000 - 26.033 mm (1.0236 - 1.0249 in) Push rod 1. Inspect push rod for excessive wear on the face. 2. Replace if worn or damaged beyond repair. 3. Check push rod for bend using a dial gauge. Maximum allowable bend (Total indicator reading): Lessthan 0.5 mm (0.020 in)

ROCKER SHAFT AND ROCKER ARM 1. Check valve rockers, brackets and rocker shafts for scoring, wear or distortion. Replace if necessary.

EM-19

CYLINDER HEAD Inspection (Cont'd)

SEM027

SEM028

)

SEM026

2. Check clearance between valve rockers and rocker shaft. If specified clearance is exceeded, replace affected valve rockers or shafts. Specified clearance: Limit TD27 Less than 0.20 mm (0.0079 in) BD30 Lessthan 0.15 mm (0.0059 in) Rocker shaft outer diameter "A": Standard 19.979 - 20.000 mm (0.7866 - 0.7874 in) Rocker arm inner diameter "B": Standard 20.02 - 20.04 mm (0.7882 - 0.7890 in)

3. Check rocker shaft bend at its center. If bend is within specified limit, straighten it; and if it is greater than specified limit, replace rocker shaft. Rocker shaft bend (Total indicator reading): Limit TD27 Lessthan 0.10 mm (0.0039 in) BD30 Less than 0.60 mm (0.0236 in) MEASURING CYLINDER HEAD TO VALVE DISTANCE Measure distance from cylinder head surface to intake and exhaust valves. If specified distance is exceeded, replace valve(s) or valve seat(s). Specified distance: Standard Intake TD27 0.225 - 0.725 mm (0.0089 - 0.0285 in) BD30 0.725 - 1.225 mm (0.0285 - 0.0482 in) Exhaust TD27 0.255.0.745 mm (0.0100 - 0.0293 in) BD30 0.755 - 1.245 mm (0.0297 - 0.0490 in)

EM-20

CYLINDER HEAD

Inspection (Cont'd) Limit Intake and exhaust valves Lessthan 1.25 mm (0.0492 in)

Assembly 1.

Assemble rocker shaft component parts.

Identification of rocker arms: Identification mark (on rocker arm)

For use with

Intake

Exhaust

SEM700C

2. Install valve component parts. Identification of valves: Identification mark (on intake and exhaust valve) Intake valve

Exhaust valve

•

Always use new valve 011 seal. (Refer to OIL SEAL REPLACEMENT.)

•

Install valve spring (uneven pitch type) with Its narrow pitch side toward cylinder head side.

SEM926B

Wide pitch

Narrow pitch

•

Cylinder head side

SEM638B

EM-21

CYLINDER HEAD Installation 1.

(On-vehicle service)

Install cylinder head gasket.

Identification

of cylinder head gaskets

Identification cut hole (on cylinder head gasket)

SEM600C

a. b.

Measuring points

Front

Inner diameter "d" mm (in)

Engine

97.5 (3.839)

TD27

When replacing only cylinder head gasket, install same grade gasket as the one formerly used. When replacing or repairing cylinder block, cylinder head, piston, connecting rod and crankshaft, select gasket as follows:

(1) Measure piston projection. • Set each piston at its Top Dead Center. With piston held in that position, measure its projections at two points. • Calculate the average value of the two measurements. • Determine the amount of projection of the other three pistons. (2) Select suitable cylinder head gasket which conforms to the largest amount of projection of the four pistons. Unit:

T027

mm (in)

SEM640B

Average values piston projections

8030

Gasket th ickness

Less than 0.118 (0.0046)

1.30 (0.0512)

0.118 - 0.168 (0.0046 - 0.0066)

1.35 (0.0531)

More than 0.168 (0.0066)

1.40 (0.0551)

8030

Unit: mm (in)

,/L--, Engine ~

front SEM702C

Gasket grade number

Average values piston projections

Gasket thickness (nominal dimension)

Gasket grade number

Less than 0.44 (0.0173)

1.20 (0.0472)

0.44 - 0.49 (0.0173 0.0193)

1.25 (0.0492)

More than 0.49 (0.0193)

1.30 (0.0512)

Make sure that No. 1 piston Is at T.O.C. on Its compression stroke.

EM-22

CYLINDER HEAD Installation (On-vehicle service) (Cont'd) 2. Install cylinder head. Cylinder head identification mark: Identification number (on cylinder head)

Engine

Float mark

Punch mark

T027

8030

Apply oil to the thread portion and seat surface of bolts and tighten cylinder head bolts using Tool.

CAUTION: Tightening procedure 1st: 2nd: Tighten in numerical order.

Tighten bolts to 39 - 44 N.m (4.0 - 4.5 kg-m, 29 - 33 ft.lb) Tighten bolts to 54 - 59 N.m (5.5 - 6.0 kg-m, 40 - 43 ft-Ib)

3rd:

SEM641 B

(1) Mark exhaust side of cylinder head and cylinder head bolts with paint asshown. (2) Turn all bolts 90:!::10degreesclockwise. (3) Check that the paint mark of each bolt is facing the front of the vehicle.

Engine front

@(j)@@@@ Tighten in numerical order.

SEM703C

4. 5.

Apply engine oil and install push rods. Install rocker shaft assembly. Rocker shaft bracket bolt: ~: 20 ~ 25 N'm (2.0 - 2.5 kg-m, 14 - 18 ft-Ib) Adjust intake and exhaust valve clearances temporarily. Refer to section ET.

EM-23

CYLINDER HEAD

Installation (On-vehicle service) (Cont'd) 6. â&#x20AC;˘

Install rocker cover with rocker cover plate (TD27). Be sure the "F" mark on rocker cover plate faces upward and is at the front end.

â&#x20AC;˘

When replacing rocker cover gasket, bend slit of rocker cover baffle plate a little to hold the gasket. Do not twist gasket.

Rocker cover gasket

SEM643B

8030

Rocker cover

~ SEM705C

Install glow plugs and glow plate (TD27). Glow plug:

15 - 20 N.m (1.5 - 2.0 kg-m, 11 - 14 ft-Ib)

~ SEM618B

Install new top nozzle gasket and injection nozzle.

Injection nozzle holder: ~:44 - 49 N.m (4.5 - 5.0 kg-m, 33 - 36 ft-Ib)

Install spill tube and injection tube.

Spill tube fixing nut:

COJ : 29 - 39 N.m (3.0 - 4.0 kg-m, 22 - 29 ft-Ib) Injection tube flared nut: ~: 20 - 25 N.m (2.0 - 2.5 kg-m, 14 - 18 ft-Ib)

EM-24

CYLINDER HEAD Installation (On-vehicle service) (Cont'd) 10. Connect thermostat

housing water

inlet

hose and radiator

hose. 11. After

assembling all disassembled parts, fill

engine with new coolant up to filler opening.

EM-25

radiator

and

OIL SEAL REPLACEMENT (On-vehicle service) OIL SEAL INSTALLING DIRECTION When installing a new front or rear seal, make sure its mounting direction is correct. Engine. inside

Engine outside

CRANKSHAFT FRONT OIL SEAL 1. Remove counterweight. 2. Remove radiator shroud and radiator. 3. Remove muffler. 4. Remove cooling fan. 5. Remove drive belts. 6. Remove crank pulley. 7. Remove crankshaft oil seal. Be careful not to damage sealing surfaces of crankshaft. 8. Coat new oil seal with engine oil and install it in place.

VALVE STEM OIL SEAL 1. Remove rocker cover. 2. Remove rocker shaft assembly. 3. Remove valve spring.

Remove valve oil seals.

EM-26

OIL SEAL REPLACEMENT (On-vehicle service) 5.

Apply engine oil to valve oil seal and install it in place.

Cylinder head or spring seat SEM565E

EM-27

ENGINE OVERHAUL

Idler gear securing bolt ~ 25 - 35 (2.6 - 3.6, 19 - 26) (T027) ~23 - 30 (2.3 - 3.1,17 - 22) (8030) Injection pump gear Oil pump

Idler gear plate Washer Injection pump gear securing nut ~59 - 69 (6.0 - 7.0, 43 - 51)

Idler gear Front plate

...~'"

0"'''' p'''' ~

Dust cover

~~~ ~

13 - 19

(1'3-1~9' 9 - 14) ~

1""~\ \

Front cover ~' a-ring ~

~ Washer PTO i~ler gear securing nut

Idler

Key ~.crank.gear

, " (PTO)

~~...../011

•

Camshaft gear ~

f!;j ~~---~

Jet ~~ _ 49 Idler shaft securing bolt (4.5 - 5.0, Snap ring; Bolt 33 - 36) Bearing Washer . Bolt Snap ring ~

• ~ ,:\)

@i rl

~~~

i~~,

~ ~ '\ ,

ear (PTO)~ go, ~

~/Bolt

9~ •

Piston pin

Connecting rod

Dummy (to be Connecting rod , removed after bearing O-ring installing oil pump) Oil jet-~

Adapter (for hydraulic pump) , a-ring Bearing

Piston ring

Piston

4 - 6 (0.4 - 0.6, 2.9 - 4.3)

29 - 39 ~ (3.0 - 4.0, 22 _ 29)

~c:~:y~~ ~ (30 - 33, ~ 217 - 239)

Crankshaft

.....\~ ~

~167 - 1n (17.0 - 18.0, 123 - 130)

Oil pan ~7-9

~ (0.7 - 0.9, 5.1 - 6.5)

N.m (kg-m, ft-Ib) recommended sealant. (Nissan genuine part: KP610-00250) or equivalent. ~ : Always replace when disassembled, l' : Keep in correct order.

D : Apply

<Q>

.- .. 54 - 59~ (5.5 - 6.0, 40 - 43)

FEM178

EM-28

ENGINE OVERHAUL

Disassembly PISTON AND CRANKSHAFT 1. Remove oil filter. 2. Place engine on work stand.

SEM650B

Attachment

installation

hole

FEM179

Coolant

drain plug.

3. 4. 5. 6.

Drain coolant and oil. Remove drive belts. Remove cylinder head. Remove oil pan.

Remove crank pulley.

8. 9.

Remove water pump. Remove front cover.

= FEM180

SEM652B

EM-29

ENGINE OVERHAUL Disassembly (Cont'd) " the timing case Is hard to remove due to liquid gasket, pry It off with a suitable tool at the cutout section.

SEM676B

10. Remove injection pump gear.

SEM653B

11. Remove idler gear and idler gear shaft. 12. Remove camshaft gear, camshaft and valve lifters.

SEM655B

13. Remove oil pump assembly.

EM-30

ENGINE OVERHAUL Disassembly (Cont'd) 14. Remove PTO gear, PTO idler gear and PTO crankshaft gear.

15. Remove 16. Remove 17. Remove 18. Remove

crankshaft gear. flywheel and rear plate. connecting rod caps. pistons.

19. Remove rear oil seal retainer.

SEM6578

20. Remove bearing cap and crankshaft. Place the bearings and caps in their proper order.

Loosen in numerical order.

SEM6588

EM-31

ENGINE OVERHAUL

1t~Qtt

---:

Measuring point

~-(

Inspection and Replacement CYLINDER BLOCK DISTORTION If beyond the specified limit, replace it. Cylinder block distortion: Standard Less than 0.05 mm (0.0020 In) Limit 0.2 mm (0.008 In)

~({~ SEM038

CYLINDER LINER WEAR 1.

Unit:

mm (in)

FEM182

projectio~

Measure cylinder liner bore for out-of-round and taper with a bore gauge. If beyond the limit, replace cylinder liner. Inside diameter (With cylinder liner for factory): 96.000 - 96.030 mm (3.7795 - 3.7807 in) Refer to S.O.S. Inside diameter (WIth cylinder liner for service): 96.025 - 96.070 mm (3.7805 - 3.7823 in) Wear limit: 0.20 mm (0.0079 In) Out-of-round (X - Y) limit: 0.040 mm (0.0016 in) Taper (A - B) limit: 0.040 mm (0.0016 in) Check for scratches or seizure. If seizure is found, replace cylinder liner.

Check amount of projection of cylinder liner. Cylinder liner projection: Standard 0.02 - 0.09 mm (0.0008 - 0.0035 In) Deviation of each cylinder: Less than 0.05 mm (0.0020 In)

CYLINDER LINER Replacement 1. Remove cylinder liner with Tool.

SEM849

EM-32

ENGINE OVERHAUL

Inspection and Replacement (Cont'd) 2. 3.

Install cylinder liner with Tool. Check amount of projection of cylinder liner.

SEM659B

PISTON TO CYLINDER WALL CLEARANCE 1.

SEM660B

Measure piston and cylinder bore diameter. Piston diameter "A": Refer to S.O.S. Measuring point "a" (Distance from the top): T027 70 mm (2.76 In) B030 63.5 mm (2.500 in) Check that piston clearance is within the specification. Piston clearance: 0.05 - 0.07 mm (0.0020 - 0.0028 in)

PISTON AND PISTON PIN CLEARANCE Check clearance between pistons and piston pins. Clearance (B - A): Standard -0.003 to 0.012 mm (-0.0001 to 0.0005 In) Limit Less than 0.1 mm (0.004 In)

SEM424

EM-33

ENGINE OVERHAUL

Inspection and Replacement (Cont'd) PISTON RING SIDE CLEARANCE Side clearance: Top ring

mm (0.0024.0.0039

In)

0.04 • 0.08 mm (0.0016.0.0031

In)

0.06.0.10 2nd ring

all

ring

0.02 • 0.06 mm (0.0008 • 0.0024 In) Max. limit of side clearance: Top

0.5 mm (0.020 In) 2nd

0.3 mm (0.012 in)

all 0.15 mm (0.0059 in)

PISTON RING GAP Install piston rings in grooves on cylinder liner within a range of 20 mm (0.79 in), as shown, before measuring piston ring gaps. Ring gap (With cylinder liner for factory): Top ring

0.30 • 0.45 mm (0.0118.0.0177 ~~Cl

Cylinder liner Unit: mm (in)

SEM004E

In)

2nd ring

0.30 • 0.45 mm (0.0118 • 0.0177 in) Oil ring T027

0.25 • 0.45 mm (0.0098 • 0.0177 in) 8030 0.20 • 0.45 mm (0.0079 • 0.0177 in) Max. limit of ring gap:

1.5 mm (0.059 In) Ring gap (With cylinder Top ring

0.40.0.60

liner for service):

mm (0.0157 • 0.0236 In)

2nd ring

8030 0.30 • 0.50 mm (0.0118 • 0.0197 In) T027

0.60 • 0.80 mm (0.0236 • 0.0315 In) Oil ring

0.40 • 0.65 mm (0.0157 • 0.0256 in) Max. limit of ring gap:

1.5 mm (0.059 In)

EM-34

ENGINE OVERHAUL Inspection and Replacement

(Cont'd)

MAIN BEARING CLEARANCE Main bearing clearance: Standard 0.035 . 0.087 mm (0.0014 . 0.0034 In) Limit Less than 0.15 mm (0.0059 In)

Install main bearings to cylinder block and main bearing cap. 2. Install main bearing cap to cylinder block. Tighten all bolts In correct order and In two or three stages. 3. Measure inside diameter "A" of main bearing.

Measure outside diameter "Dm" of main journal in crankshaft.

Calculate main bearing clearance. Main bearing clearance = A - Dm

CONNECTING ROD BEARING CLEARANCE Connecting rod bearing clearance: Standard 0.035 - 0.081 mm (0.0014. 0.0032 In) Limit Less than 0.15 mm (0.0059 In) 1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap to connecting rod.

EM-35

ENGINE OVERHAUL Inspection and Replacement

(Cont'd)

Apply 011to the thread portion of bolts and seating surface of nuts. 3. Measure inside diameter "A" of bearing. 4. Measure outside diameter "Op" of pin journal in crankshaft. 5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = A - Op

SEM507A

CONNECTING ROD BEND AND TORSION Bend and torsion: Limit 0.05 mm (0.0020 in) per 100 mm (3.94 in) length

EM133

CONNECTING ROD SMALL END BUSHING CLEARANCE 1.

Measure inside diameter "A" of connecting rod small end bushings.

2. 3.

Measure outside diameter "0" of piston pin. Calculate connecting rod small end bushing clearance. Connecting rod small end bushing clearance = A - 0 Bushing clearance: Standard 0.025 - 0.045 mm (0.0010 - 0.0018 In) Limit 0.15 mm (0.0059 In)

SEM781B

EM-36

ENGINE OVERHAUL Inspection and Replacement (Cont'd) REPLACEMENT OF CONNECTING ROD SMALL END BUSHING 1.

SEM062A

Drive in the small end bushing until it is flush with the end surface of the rod. Be sure to align the 011holes. 2. After driving in the small end bushing, ream the bushing. Small end bushing Inside diameter: Finished size: T027 28.025 - 28.038 mm (1.1033.1.1039 in)

8030 30.025 . 30.038 mm (1.1821 - 1.1826 in)

Out-of-round Taper

CRANKSHAFT

X- Y A - B

1. 2.

EM715

SEM662B

Check crankshaft journals and pins for score, bias, wear or cracks. If faults are minor, correct with fine crocus cloth. Check journals and pins with a micrometer for taper and out-of-round. Out-of-round (X - Y): Standard Less than 0.01 mm (0.0004 In) Limit 0.02 mm (0.0008 In) Taper (A - B): Standard Less than 0.01 mm (0.0004 In) Limit 0.02 mm (0.0008 In)

Check crankshaft runout. Runout [T.I.R. (Total Indicator Reading)] Standard 0.0.03 mm (0 - 0.0012 In) Limit 0.10 mm (0.0039 In)

ENGINE OVERHAUL

Inspection and Replacement (Cont'd) RESURFACING OF CRANKSHAFT JOURNAL AND CRANK PIN

LLLL O.K.

N.G.

SEF692A

When using undersize main bearings and connecting rod bearings, the crankshaft journals or crank pins must be finished to match the bearings. R: Crank Journal: 3.0 mm (0.118 In) Crank pin: 3.5 mm (0.138 In) CAUTION:

a. At the same time make sure that the surface width does not increase. b. Do not attempt to cut counterweight of crankshaft. CRANKSHAFT PilOT BUSHING Crankshaft pilot bushing replacement

5.8 - 6.0 mm (0.228 - 0.236 In)

Pull out bushing with Tool.

Insert pilot bushing until distance between flange end and bushing is specified value. Distance: Approx. 5.8 • 6.0 mm (0.228 • 0.236 In)

FLYWHEEL RUNOUT Runout (Total Indicator reading): Less than 0.10 mm (0.0039 In)

SEM059A

FRONT PLATE Check front plate for warpage. If not within the limit, make flat or "replace front plate. Warpage limit: 0.2 mm (0.008 In)

SEM6688

EM-38

ENGINE OVERHAUL

Inspection and Replacement (Cont'd) GEAR TRAIN Camshaft drive gear, injection pump drive gear, oil pump gear, Idler gear and crankshaft gear 1. 2.

If gear tooth and key have scratches or are excessively worn, replace gear and key. Check gear train backlash before disassembling and after assembling. Method A (Using dial gauge) Method B (Using fuse wire) If beyond the limit, replace gear. Backlash:

Standard T027

0.07 . 0.11 mm (0.0028 - 0.0043 in) B030

0.06 - 0.12 mm (0.0024.0.0047

in)

limit 0.20 mm (0.0079 in)

IDLER GEAR BUSHING CLEARANCE 1.

Measure idler gear shaft outer diameter.

2. 3.

Measure idler gear bushing inner diameter. Calculate idler gear bushing clearance. Bushing 011 clearance: Standard 0.025 • 0.061 mm (0.0010 • 0.0024 In) Limit 0.20 mm (0.0079 In)

SEM666B

SEM705

IDLER GEAR END PLAY Measure idler gear end play between gear plate and gear. Idler gear end play: Standard 0.03.0.14 mm (0.0012 • 0.0055 In) Limit Less than 0.3 mm (0.012 In)

EM-39

ENGINE OVERHAUL

Inspection and Replacement (Cont'd) REPLACEMENT OF IDLER GEAR BUSHING 1. Use a suitable tool to replace bushing. 2.. Ream idler gear bushing. Finished size: 42.00 • 42.02 mm (1.6535 • 1.6543 in)

Idler gear shaft Install idler gear shaft so that oil hole of shaft faces upward.

CAMSHAFT AND CAMSHAFT BUSHING Camshaft bushing clearance

SEM669B

Measure inside diameter of camshaft bushing and outside diameter of camshaft journal with a suitable gauge. Clearance between camshaft and bushing (A - B): Standard 0.020 • 0.109 mm (0.0008 • 0.0043 in) Limit Less than 0.15 mm (0.0059 In)

REPLACING CAMSHAFT BUSHING 1.

Using Tool, remove camshaft bushings from the engine. Some bushings must be broken in order to remove.

Using Tool, install camshaft bushings as follows:

SEM106C

Cam bushing replacer set KV111045S0

Adapter I1st bushing) KV11104530

~D';h ST15243000 SEM993B

(1) Install camshaft bushings in the order of "rear", "4th", "3rd". "2nd" and "front". All bushings must be installed from the front. (2) Face the cutout upward and toward the front of the engine during installation.

Upward

Q Engine front

Front 5 SEM686B

EM-40

ENGINE OVERHAUL Inspection and Replacement

(Cont'd)

(3) Rear camshaft bushing a) Align the cutout of rear bushing with knock pin of replacer bar before installation.

Insert rear bushing with replacer bar into the engine. Install guide plate with bolt holes (on the 'TO" mark side) facing upper side of cylinder block. Tighten bolts.

Drive replacer bar until the alignment mark on replacer bar is aligned with the end of replacer guide. Remove replacer set. After installation, check that oil holes in camshaft bushings are aligned with oil holes in cylinder block.

EM-41

ENGINE OVERHAUL Inspection and Replacement

Guide plate

Alignment mark to @ surface

(Cont'd)

Rear bushing Knock pin Replacer bar

Engine front

SEM601C

(4) 4th. 3rd and 2nd camshaft bushings Install in the same manner as rear camshaft bushing.

Alignment mark to @ surface

Engine front

Alignment mark to @ surface

SEM602C

EM-42

ENGINE OVERHAUL Inspection and Replacement

(Co nt' d)

(5) Front camshaft bushing Using 1st bushing adapter. position front camshaft bushing so that oil hole in cylinder block is aligned with oil hole in bushing.

Check camshaft bushing clearance.

4. Install new welch plug with a drift. Apply liquid sealer.

Liquid sealer

When setting 4th through 2nd bushings on replacer bar, tape the bar to prevent movement.

SEM999B

EM-43

ENGINE OVERHAUL Inspection and Replacement (Cont'd) CAMSHAFT ALIGNMENT 1.

SEM670B

cam height

SEM037

SO camshaft identification

Check camshaft journal and cam surface for bend, wear or damage. If fault is beyond limit, replace. Check camshaft bend at center journal. If bend is greater than specified limit, repair or replace camshaft. Camshaft bend (Total Indicator reading): Standard Less than 0.02 mm (0.0008 In) Limit Lessthan 0.03 mm (0.0012 in)

Measure camshaft end play between locating plate and gear. If beyond the specified limit, replace camshaft locating plate. Camshaft end play: Standard 0.08 - 0.28 mm (0.0031 - 0.0110 In) Limit Less than 0.5 mm (0.020 In)

Measure camshaft cam height. If beyond the specified limit, replace camshaft. earn height: Standard Intake 41.88 - 41.92 mm (1.6488 - 1.6504 in) Exhaust 41.88 - 41.92 mm (1.6488.1.6504 in) Limit Intake Lessthan 41.4 mm (1.630 in) Exhaust Less than 41.4 mm (1.630 in)

SEM717C

EM-44

ENGINE OVERHAUL 1D27

Assembly

Leaf type combustion chamber

PISTON

Grade mark (Left direction) Engine front

Assemble pistons, piston pins, snap rings and connecting rods. a. Numbers are stamped on the connecting rod and cap corresponding to each cylinder. Care should be taken to avoid a wrong combination Including bearing.

Matching mark (Cylinder No.) SEM672S

8D30

Grade mark

Engine front

c::? Matching mark (cylinder No.) SEM718C

When Inserting piston pin In connecting rod, heat piston with a heater or hot water [approximately 60 to 70Â°C (140 to 158Â°F)] and apply engine 011 to pin and small end of connecting rod. After assembling, ascertain that piston swings smoothly.

SEM292

Install piston assembly. CAUTION: a. Stretch the piston rings only enough to fit them In the piston grooves. b. Be sure the manufacturer's mark faces upward.

White paint""/ identification mark (2nd piston ring only)

Identification of top piston ring and second piston ring.

Punch mark side up (Both top and second piston rings) SEM005E

EM-45

ENGINE OVERHAUL Assembly (Cont'd) d.

Ring gap direction

TD27

Install No.1 piston ring In such a way that Its gap faces the direction of the piston pin; and then Install piston rings so that their gap positioned at 180 to one another. 0

8D30 Identification mark

Top and oil ring 2nd ring Engine front Piston grade number SEM719C

CRANKSHAFT 1. Install crankshaft. (1) Set main bearings in the proper position on cylinder block. a. If either crankshaft, cylinder block or main bearing Is reused again, It Is necessary to measure main bearing clearance. b. Upper bearings have 011 hole and 011 groove, however lower bearings do not.

(2) Apply engine oil to crankshaft journal and pin and install crankshaft. (3) Install main bearing caps. a) Install main bearing cap with the number facing the front of vehicle. b) Apply engine oil to main bearing cap and cylinder block contact surfaces. c) Install rear oil seal assembly. Apply engine oil to contact surface of rear end oil seal and crankshaft.

Engine front

SEM6748

(4) Install crankshaft thrust washer at the 4th journal from front. Install thrust washer so that 011 groove can face crankshaft.

SEM057

EM-46

ENGINE OVERHAUL

Assembly (Cont'd) (5) Tighten bearing cap bolts gradually in stages, starting from two to three separate stages, from center bearing and moving outward in sequence.

Tighten in numerical order.

SEM675B

(6) Measure crankshaft free end play at No.4 bearing. Crankshaft free end play: Standard 0.055.0.180 mm (0.0022.0.0071 In) Limit 0.4 mm (0.016 In) If beyond the limit, replace No.4 main bearing thrust washer. Refer to S.O.S.

SEM063

2. (1) • • •

Engine front

Install pistons with connecting rods. Install them into corresponding cylinder using Tool. Be careful not to scratch cylinder wall with connecting rod. Apply engine 011 to cylinder wall, piston and bearing. The leaf type combustion chamber on piston head must be at right side of engine.

SEM453

(2) Install connecting rod bearing caps.

Hino engine parts Mitsubishi engine parts Nissan engine parts for heavy equipment Contact: EngineParts@HeavyEquipmentRestorationParts.com SEM678B

EM-47

ENGINE OVERHAUL Assembly (Cont'd) 3.

Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.10.0.22 mm (0.0039.0.0087 In) Limit 0.22 mm (0.0087 In) If beyond the limit, replace connecting rod and/or crankshaft.

GEAR TRAIN Idler gear

1. 2.

Set NO.1 piston at its top dead center. Align each gear mark and install gears.

SEM665B

TIMING GEAR CASE Installation 1.

Before installing timing gear case, remove all traces of liq~ uid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of front plate.

Apply a continuous bead of liquid gasket to mating surface of timing gear case.

SEM680B

SEM681B

EM-48

ENGINE OVERHAUL Assembly (Cont'd)

-----

Application portion

SEM682B

• • Cut here

.~-----J

• •

Be sure liquid gasket Is 2.5 to 3.5 mm (0.098 to 0.138 In) wide. AUach timing gear case to front plate within 10 minutes after coating. Walt at least 30 minutes before refilling engine coolant or starting engine. Use Genuine Liquid Gasket or equivalent.

Liqu id gasket

SEM683B

EM-49

SPECIAL SERVICE TOOLS ': 5pecial tool or commercial Tool number Tool name

equivalent Engine application

Description

5T05015000' Engine stand assembly (1) 5T05011000 Engine stand @ 5T05012000

Disassembling assembling

TD27

BD30

and

Base

KV10106500' Engine attachment

KV11103200' Engine sub-attachment

~~ KV10109250 (1) KV10109210' Valve spring compressor @ KV10111200'

Disassembling and assembling valve components

Adapter

~ KV10107900' Valve oil seal puller

Disassembling seal

KV11103400 Valve oil seal drift

valve oil

Installing valve oil seal

5T11033000' Valve guide drift

Removing valve guide

KV11103900' Valve gUide drift

Installing valve guide

EM-50

SPECIAL SERVICE TOOLS *: Special tool or commercial

Tool number Tool name

equivalent Engine application

Description

ST11032000' Valve guide reamer 8.0 mm (0.315 in) dia.

Reaming valve guide

G) KV11101110 Valve seat remover @ KV11103510 Adapter (Intake) @ KV11103520 Adapter (Exhaust) @ KV11104910

Removing valve seat

TD27

BD30

CD 2 @@@@CV

Adapter (Intake)

@ KV11104920 Adapter (Exhaust)

@ KV11103610 Adapter (Intake) (f) KV11103620 Adapter (Exhaust) G) ST15243000 Valve seat drift @ KV11103710

Installing valve seat

Adapter (Intake)

@ KV11103720 Adapter (Exhaust)

@ KV11103810

Adapter (Intake) @ KV11103820 Adapter (Exhaust)

~ G) KV11104010 Cylinder liner tool @ KV11104020 Adapter for removing @ KV11104700

@@ Removing and installing cylinder liner

@@@

tJ,@

Adapter for removing @ KV11104110

Adapter for removing

@ KV11104030 Adapter for installing

Installing piston into cylin-

EM03470000' Piston ring compressor

der

EM-51

SPECIAL SERVICE TOOLS *: Special tool or commercial

Tool number Tool name

equivalent Engine application

Description TD27

8030

Preventing crankshaft from rotating

KV111033S0 Engine stopper G) KV11103310 Stopper plate @ KV10105630 Stopper gear

ST16610001' Pilot bushing puller

Removing pilot bushing

KV111045S0 eam bushing replacer set G) KV11104510

Removing cam bushing or installing cam bushing

Replacer bar

@ KV11104520 Guide plate

@ KV11104530 Adapter (1st bushing) @ ST15243000 Drift

KV10109300' Injection pump drive gear holder

Preventing drive gear from rotating (VE-type)

KV11103000' Injection pump drive gear pUller

Removing drive gear (VEtype)

WS39930000' Tube presser

Pressing the tube of liquid gasket

EM-52

SPECIAL SERVICE TOOLS

Tool number Tool name

Engine application Description

ED19601000 Compression gauge

TD27

8D30

Checking compression pressure

ED19600600 Compression gauge adapter (for glow plug hole)

Checking compression pressure

ED19600700 Compression gauge adapter (for injector hole)

Checking compression pressure

ED19600800 Compression gauge adapter (for injection hole)

Checking compression pressure

DK57914010 Socket wrench (For timer round nut)

Removing and installing injection pump assembly

KV11226582 Timer extractor

Removing injection pump assembly

EM-53

SERVICE DATA AND SPECIFICATIONS Engine Lubrication System OIL PRESSURE CHECK

TIGHTENING

Engine rpm

Approximate discharge pressure kPa (bar, kg/em' , psi)

Idle speed 3,000

98 (0.98, 1.0, 14) 294 - 441 (2.94 - 4.41,3.0 - 4.5, 43 - 64)

OIL PUMP INSPECTION

Unit:

mm (in)

Gear side clearance

0.05 - 0.13 (0.0020 - 0.0051 )

Gear backlash

0.07. 0.11 (0.0028 - 0.0043)

Oil pump bushing clearance

TORQUE

Unit

N'm

kg-m

ft-Ib

Oil pump fixing bolt

13 -19

1.3 -1.9

9 -14

Oil cooler securing bolt

16 - 21

1.6 -2.1

12 -15

Oil filter bracket fixing bolt

16 -21

1.6 - 2.1

12 - 15

Oil jet bolt (for piston)

29 -39

3.0 -4.0

22 - 29

Oil pump relief valve

29 - 49

3.0 - 5.0

22 - 36

Oil cooler short valve

29 -49

3.0 - 5.0

22 - 36

Regulator valve

29 -49

3.0 - 5.0

22 - 36

Less than 0.15 (0.0059)

Oil pump bushing inside diameter

13.012 -13.098 (0.5123 -0.5157)

Drive gear shaft outside diameter

12.974 - 12.992 (0.5108 - 0.5115)

Engine Cooling System TIGHTENING

THERMOSTAT Valve opening temperature

Â°c Max. valve lift

mmtc

82 (180)

(0 F)

(intF)

8/95 (0.31/203)

TORQUE

Unit

N'm

kg-m

ft-lb

Water pump M8

16 - 21

1.6 -2.1

12 - 15

30 -41

3.1 -4.2

22 - 30

16 - 21

1.6.2.1

12 -15

Ml0 Thermostat housing bolt

RADIATOR Cap relief pressure Leakage test pressure

Unit:

kPa (bar, kg/em',

psi)

78 -98 (0.78 - 0.98, 0.8 -1.0, 11 -14) 98 (0.98, 1.0, 14)

LC-2

Water outlet bolt

16 - 21

1.6 -2.1

12 -15

Fan securing bolt

7 -9

0.7 -0.9

5.1 - 6.5

Cylinder block drain plug

20 - 29

2.0 - 3.0

14 - 22

Water temperature sensor

20 - 29

2.0 - 3.0

14 - 22

ENGINE LUBRICATION SYSTEM Lubrication Circuit Oil cooler assembly

Oil jet (for piston & cylinder) Oil jet (for gear train)

Note:

~ -4-

Oil gallery -- -

in cylinder

block

By-pass passage

Oil passage

________

Return to oil pan

Engine oil cooler

------j

Regulator valve

"--I

-l I

Oil

Oil strainer

pan

_lJ

FEL030

LC-5

ENGINE LUBRICATION SYSTEM 011 Pressure Check (On-vehicle service) WARNING: a. Be careful not to burn yourself, as the engineand oil may be hot. b. Oil pressure check should be done in "Neutral" gear position.

1. Check oil level. 2. Remove oil pressure

3. 4. 5.

switch.

Install pressure gauge. Start engine and warm it up to normal operating temperature. Check oil pressure with engine running under no-load.

Engine rpm

Approximate discharge pressure kPa (bar, kg/cm2 , psi)

Idle speed

98 (0.98, 1.0, 14)

3,000

294.441 (2.94 . 4.41, 3.0 . 4.5, 43 . 64)

If difference is extreme, check oil passage and oil pump for 011 leaks. 6.

Install oil pressure

switCh.

Use proper liquid sealant. Oil pressure switch: ~ : 10 â&#x20AC;˘ 13 N.m (1.0 - 1.3 kg-m, 7 - 9 ft-Ib)

LC-6

ENG INELU BRI CATION SYSTEM Oil Pum

Oil pump-

SLC020A

OIL PUMP INSPECTION 1. Insf?ect pump body, gears and drive shaft for wear and damage. 2. Using a feeler gauge and fuse wire, check the following clearances. Gear side clearance: 0.05 - 0.13 mm (0.0020 - 0.0051 in)

Gear backlash: 0.07 - 0.11 mm (0.0028 - 0.0043 in)

SLC967

Measure inside diameter "A" of bushing. A: 13.012 - 13.098 mm (0.5123 - 0.5157 in)

LC-7

ENGINE LUBRICAT.lON SYSTEM Oil Pump (Cant'd) 4. 5.

Measure outside diameter "8" of drive gear shaft. B: 12.974 - 12.992 mm (0.5108.0.5115 in) Calculate oil pump bushing clearance. Oil pump bushing clearance: A - B Less than 0.15 mm (0.0059 in)

SLC969

If it exceeds the limit, replace oil pump bushing or entire oil pump assembly.

SLC965

LC-8

ENGINE LUBRICATION SYSTEM Oil Filter Bracket

III

/@(,

all pump """""

(For loading pump lubrication) ...

Bolt (6) 16.19 (1.6.1.9.12.14)

: Always replace after every disassembly.

: N.m (kg-m, ft-Ib)

.~(~"..

~""k:;~tM

b~k"

;ket Oil filter

FEL031

OIL PUMP RELIEF VALVE INSPECTION 1. Visually inspect components for wear and damage. 2. Coat relief valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If damaged, replace oil pump relief valve set.

OIL FILTER RELIEF VALVE INSPECTION Inspect oil filter short valve for movement, cracks and breaks by pushing the ball. If damaged, replace oil filter bracket assembly.

LC-9

ENGINE LUBRICATION

SYSTEM

Oil Cooler

Regulator valve-

- Oil cooler elel'T)ent ~

: N.m (kg-m, ft.lb)

SLC973

OIL COOLER RELIEF VALVE INSPECTION Inspect oil cooler relief valve for movement, cracks and breaks by pushing the ball. If damaged, replace oil cooler relief valve set.

REGULATOR VALVE INSPECTION 1. Visually inspect components for wear and damage. 2. Coat regulator valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set.

LC-10

ENGINE LUBRICATION SYSTEM Oil Jet INSPECTION Gear train Make sure that the holes are not clogged. Clean them with a wire if necessary.

Oil jet has to be installed with oil hole facing crank gear and idler gear.

Piston 1. Blow through outlet of oil jet and make sure that air comes out of inlet. 2. Push cut-off valve of oil jet bolt with a clean resin or brass rod and make sure that cut-off valve moves smoothly with proper repulsion.

When installing oil jet, align oil jet's boss with hole on cylinder block. Oil jet bolt: ~: 29-39N.m (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)

Dimension "0": 12 mm (0.47 in)

SLC325A

LC-11

COOlIN6,SYSTEM Cooling Circuit

Water pump assembly

Radiator

t Thermostat housing

â&#x20AC;˘

t Water outlet

Water pump

{7 Engine oil cooler

Cylinder block

Thermostat

t Cylinder head

<$'

Under cold conditions

LC..12

COOLING SYSTEM Cooling System Inspection CHECKING

HOSES

Check hoses for proper attachment, connections,

chafing and deterioration.

CHECKING

RADIATOR

Apply

pressure to radiator

leaks, cracks, damage, loose

CAP cap by means of a cap tester to see if

it is satisfactory.

Radiator cap relief pressure: 78.98 kPa (0.78 .0.98 bar, 0.8 . 1.0 kg/cm2

CHECKING Apply

11 . 14 psi)

COOLING SYSTEM FOR LEAKS

pressure to the cooling

system by means of a tester to

check for leakage.

Testing pressure: 98 kPa (0.98 bar, 1.0 kg/cm2

, 14 psi) CAUTION: Higher than the specified pressure may cause radiator damage.

SMA990A

LC-13

COOLING SYSTEM Water Pump REMOVAL AND INSTALLATION Drain coolant from drain plugs on cylinder block and radiator. Cylinder block drain plug (Use proper sealant): ~: 20 - 29 N.m (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)

Nut (2)

t"J 26 - ,.

"_7 - 3.7. 20 - 27' ~

Water pump gasket ~

\8011151 ~

: Always replace after every disassembly"

: N.m (kg-m, ft-Ib)

13.19 (1.3.1.9, 9.14)

FCD024

CAUTION: a. When removing water pump assembly, be careful not to get coolant on drive belt. b. Water pump cannot be disassembled and should be replaced as a unit. c. Always replace with new gasket. d. After installing water pump, connect hose and clamp secure. Iy, then check for leaks using radiator cap tester.

LC-14

COOLING SYSTEM

Water Pump (Cont'd) INSPECTION

1. Check for badly rusted or corroded body assembly and vane.

2. Check for rough operation due to excessive end play.

FCD025

3. Check fan coupling for rough operation, oil leakage or bent bimetal. The water pump and fan coupling cannot be disassembled and should be replaced as a unit.

Water Outlet and Thermostat Bolt Harness Clamp~tDJ'3-

Water outlet~YBOIt

19 (1.3 ,'.9,

9.14)

(2) tDJ13 - 19 (1.3 - 1.9,9 - 14)

F1f.

~Ga""

///1I

Therm~:~~~ostat housing Bolt tDJ 13 - 19 (1.3 - 1.9, ~ 9 - 14) Bolt 9 - 14)

()XJ/

()

@i7t~ Y0~... /1 i >.

•

<", •••

A13-'911_3-'_9.9-141~<¥'

Cylinder head Washer

_ \-.,

Bolt

OPT :~";"'~

tDJ 15-25 (1.5-2.5,1'-'8)

~-'

Thermal transmitter

~ Prl'I

.-J

: Always replace after every disassembly. : N.m (kg-m, ft.lb)

b 1...1 Rub er sea

• •

~It.

(2) Prl'I 13.19 (1.3.1.9,9

.-J

tDJ 15-20 (1.5-2.0, - 14)

'1-14) FCD026

After installation, run engine for a few minutes, and check for leaks. Be careful not to spill coolant over engine compartment. Place a rag to absorb coolant.

LC-15

COOLING SYSTEM Water Outlet and Thermostat (Cont'd) INSPECTION 1. Check for valve seating condition at ordinary temperatures. It should seat tightly. 2. Check valve opening temperature and maximum valve lift.

°c

Valve opening temperature Max. valve lift

SLC343

mmtC

(oF)

(intF)

82 (l80) 8/95 (0.31/203)

3. Then check if valve closes at 5°C (9° F) below valve opening temperature.

Radiator WARNING: To avoid serious personal injury, never remove radiator cap quickly when engine is hot. Sudden release of cooling system pressure is very dangerous. If it is necessary to remove radiator cap. when radiator is hot, cover the cap with waste cloth and turn cap slowly counterclockwise to the first stop. After all pressure in the cooling system is released, turn cap passing the stop and remove it. INSPECTION Checking radiator cap Refer to section ET.

Checking cooling system for leaks Refer to section ET.

LC-16

SPECIAL SERVICE TOOLS

Tool number Tool name

Description

ST25051001 Oil pressure gauge

ST25052000 Hose

EG17650301 Radiator cap tester adapter

a uI

LC-17

Adapting oil pressure gauge to cyl inder block

Adapting radiator cap tester to rad iator fi lIer neck

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment Injection timing

mm (in)

Dimension '~K" Plunger lift

Engine

3.2 - 3.4 (0.126 - 0.134)

mm (in)

TD27

0.632 - 0.672 (0.0249 - 0.0265) . (equivalent to 5° B.T.D.C.)

BD30

1.20 - 1.24 (0.0472 - 0.0488) (equivell!ll'1ttq6° B.T.D.C.)

UK" SEF639

Adjusting shim ("B" Part number 16884.V0700 16884-V0701 16884-V0702 16884-V0703 16884.V0704 16884-V0705 16884-V0706 16884-V0707 16884-V0708 16884-V0709 16884-V0710 16884-V0711 16884- V0712

SEF016A

Use of adjustment value and adjusting shim when installing injection pump. Dimension

mm (in)

"KF"

5.7 - 5.9 (0.224 - 0.232)

position) Thickness mm(in)

1.92 2.00 2.08 2.16 2.24 2.32 2.40 2.48 2.56 2.64 2.72 2.80 2.88

_D_ie_m_n_si_on_"L_'_'

(0.0756) (0.0787) (0.0819) (0.0850) (0.0882) (0.0913) (0.0945) (0.0976) (0.1008) (0.1039) (0.1071) (0.1102) (0.1134)

Part number 16742-R8100 16742-R8101 16742-R8102 16742-R8103 167 42-R81 04 16742.R8105 16742-R8106 16742-R8107 16742-R8108 16742.R8109 16742.R8110 16742-R8111

m_m_(_in_)_1

Thickness mm (in) 1.96 2.04 2.12 2.20 2.28 2.36 2.44 2.52 2.60 2.68 2.76 2.84

(0.0772) (0.0803) (0.0835) (0.0866) (0.0898) (0.0929) (0.09611 (0.0992) (0.1024) (0.1055) (0.1087) (0.1118)

1.5 - 2.0 (0.059 - 0.079)

"L"

"KF" Adjusting

shim ("A"

SEF638

position)

Part number 16882-V0700 16882.V0701 16882-V0702 16882.V0703 16882-V0704 16882-V0705 16882-V0706

Thickness 0.5 0.8 1.0 1.2 1.5 1.8 2.0

mm (in)

(0.020) (0.031) (0.039) (0.047) (0.059) (0.071) (0.079)

SEF500

EF-2

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment (Cont'd) Axial play of flyweight holder "L"

(") mil)

0.15 . 0.35 (0.0059. 0.013S)

Flyweight holder

SEF047A

Adjusting shim Part number

Thickness mm (in)

1920S.V0700 19208.V0701 19208.V0702 1920S-V0703 19208.V0704

1.0510.0413) 1.25 (0.0492) 1.4510.05711 1.65 (0.0650) 1.S5 (O.072S)

Dimension "MS"

mm (in)

0.9. 1.1 (0.035 .0.043)

SEF856

Adjusting closing plug Part number

Length mm (in)

1626S.RS100 1626S.RS101 1626S.RS102 1626S.RS103 1626S-RS104 1626S.RS105 1626S.RS106 1626S-RS107

3.1010.1220) 3.30 (0.1299) 3.50 1O.137S) 3.7010.1457) 3.90 (0.1535) 4.10 (0.1614) 4.3010.1693) 4.50 (0.1772)

EF-3

S,~,RVICEDATA ANI;>$PECIFICATIONS Inspection" and AdJustment (Cont'd) BD30 ENGINE MODEL I njection pump assembly No. ,Part No.

Pump rotation: Clockwise-viewed from drive side] [ Pre-stroke: -

104741.4241 16700-45K01

1. Setting

Pump speed rpm

Settings

Cherge air press kPa (mbar, mmHg, inHg)

Difference in del ivery mQ (US fl OZ, Imp fl oz)

1.1

Timing device travel

900

1.6 â&#x20AC;¢ 2.0 mm (0.063 .0.079 in)

1.2

Supply pump pressure

900

235 .294 kPa (2.35 .2.94 bar, 2.4 .3.0 kg/cm' , 34 .43 psi)

1.3

Full.load delivery

800

53.6.54.6 mQ (1.81 . 1.85 US fl OZ, 1.89. 1.92 Imp fl oz)

4.0 (0.14, 0.14)

1.4

Idle sPeedregulation

350

6.5 - 10.0 mQ (0.22 .0.34 US fl OZ, 0.23.0.35 Imp fl oz)

1.5

Start

100

75.85 mQ (2.5 .2.9 US fl oz, 2.6.3.0 Imp fl oz)/1,OOO st

1.6

Full.load sPeedregulation

1,350

11.1 . 17.1 mQ (0.38.0.58 US fl OZ, 0.39 .0.60 Imp fl oz)

2.0 (0.07,0.07)

2. Test specIf ications 2.1

Timing device

N = rpm mm lin)

2.2

Supply pump

N = rpm kPa (bar, kg/cm' , psi)

2.3

Overflow del ivery

N = rpm mQ IUS fl OZ, Imp fl oz)/ 10 sec.

2 .4

Fuel del iveries

Speed control lever

End stop

Pump speed rpm

800

300 500

700 1,000

1,200

1,250 1,300 1,350

1,500

700 0.2.1.0 10.008.0.039) 700 186.245 (1.86.2.45, 1.9.2.5,27.36)

Fuel delivery mQ IUS fl OZ, Imp fl oz)/ 1,000 st 53.6.54.6 11.81 .1.85, 1.89.1.92) 38.8 n.31,1.37) 36.1.42.1 (1.22 . 1.42, 1.27 . 1.48) 50.3 11.70,1.77) 54.8 - 57.8 11.85.1.95, 1.93.2.03) 58.3.61.3 11.97.2.07, 2.05.2.16) 58.3 11.97,2.05) 40.2 11.36.1.42) 11.1.17.1 (0.38.0.58, 0.39.0.60) Below 5.0 (0.17,0.18)

350

010,0)

Idle stop

350

5.3.9.3 10.18.0.31, 0.19.0.33) Below 3.0 10.10,0.11)

2.5

Solenoid

900 235.294 (2.35.2.94 2.4 . 3.0, 34 .43)

1,100 2.6.3.4 10.102.0.134)

1,300 3.6.4.5 10.142.0.177)

1,100 275.333 (2.75.3.33 2.8.3.4,40.48)

1,200 294.353 (2.94.3.53, 3.0.3.6,43.51

1,350 3.6.4.5 10.142.0.177)

)

900 210.470 (7.1 - 15.9, 7.4.16.5)

Switch OFF

450

900 1.6.2.0 10.063 . 0.079)

Charge air press kPa Imbar, mmHg, inHg)

Difference in delivery mQ (US fl OZ, Imp fl oz)

3. Dimensions K

2.7 - 2.9 mm (0.106.0.114

4.9. 5.1 mm (0.193 . 0.201 in)

1.6.1.8

mm 10.063.0.071

8CS

Control lever angle

25.4 degree

37.5 degree

Max. cut.in voltage: 8V Test voltage: 12.14V

EF-6

in)

S~"V'CE DATA

AND SPECIFICATIONS

Inspection and Adjustment (Cont'd) Control lever angle measurement position

Measure control lever angles

(a,~)

at hole "A".

FEF167

If there is no designation in the specifications for the solenoid timer's ON-OF F position, then the position should be regarded as OFF. INJECTION

NOZZLE

Initial injection pressure kPa (bar, kg/cm2 , psi) New

Used

ASSEMBLY

Adjusting shim for injection pressure

T027

6030

10,297 - 11,278 (103.0. 112.8, 105. 115, 1,493 . 1,635)

16,182.17,162 (161.8.171.6, 165.175, 2,346 - 2,489)

9,807 (98.1,100, 1,422)

15,691 (156.9,160, 2,275)

Thickness mm (in) T027

6030

0.1 (0.004) 0.2 (0.008) 0.3 (0.012) 0.4 (0.016) 0.5 (0.020) 0.52 (0.0205) 0.54 (0.0213) 0.56 (0.0220) 0.58 (0.0228) 0.8 (0.031)

EF-7

0.5 (0.020) to 1.5 (0.059) [Every 0.025 (0.0010)]

SERVICE DATA ANDSPÂŁCIFICATIONS Tightening Torque Unit

N'm

kg-m

ft-Ib

Distributor head to pump housing

10 -14

1.0 - 1.4

7 -10

Plug to distributor head

59 - 78

6.0 -8.0

43 - 58

Del ivery valve to distributor head

44 - 54

4.5 - 5.5

33 - 40

Pivot. pin to pump h04-sing

10 - 13

1.0 -1.3

7-9

Regulating valve to pump housing

10 - 13

1.0 - 1.3

7-9

Control shaft to control lever

7 -10

0.7 - 1.0

5.1 - 7.2

Injection pump drive gear nut

59 - 69

6.0 -7.0

43 - 51

Injection pump fixing bolt

20 -25

2.0 -2.5

14 - 18

Injection pump to mounting bracket

25 - 35

2.6 -3.6

19 - 26

Injection nozzle to cy Iinder head*

54 - 64

5.5 - 6.5

40 -47

Injection tube flare nut

20 - 25

2.0 - 2.5

14 - 18

29 - 39

3.0 - 4.0

22 - 29

Feed pump cover to pump housing

2-3

0.2 -0.3

1.4 - 2.2

Speed timer cover to pump housing

6-8

0.6 -0.8

4.3 - 5.8

Governor shaft lock nut

17 - 22

1.7 - 2.2

12 - 16

Overflow valve

20 - 29

2.0 - 3.0

14 - 22

Maximum and idle speed adjusting screw lock nuts

6-9

0.6 -0.9

4.3 -6.5

Full-load adjusting screw lock nut

7-9

0.7 -0.9

5.1 -6.5

Fuel cut solenoid valve

15 - 25

1.5 - 2.5

11 - 18

. Spill tube nut

Plug bolt

14 - 20

1.4 - 2.0

10 - 14

Adjusting rod bushing lock nut

25 - 34

2.5 - 3.5

18 - 25

*. Part No. of injection nozzle: 16600-43G02

EF-8

INJECTION PUMP Removal 1. Remove injection tube.

Cover the injection nozzle assembly with a plug to prevent dust entry.

2. Remove fuel cut solenoid wire. 3. Remove accelerator wire and disconnect spill hose, fuel inlet hose and fuel return hose.

FEF157

4. Separate flare nut at injection pump.

Remove dust cover and loosen injection pump drive gear nut.

6. Confirm that No.1 piston is set at T.D.C. on its compression

stroke. Make sure that "Z" marks are aligned.

EF-9

INJECTION~UMP Removal (Cont'd) 7.

Remove rocker,oover and observe the intake and exhaust valve positions, and make sure that the matchmarks on front cover and crank pulley are aligned.

Remove injection pump drive gearby using puller.

9. Make sure that marks on injection pump and pump bracket are aligned, then remove injection pump. Do not turn crankshaft after removing injection pump.

Installation and Adjustment 1. Confirm that No. 1 piston is set at T.D.C. on its compression stroke, and temporarily set injection pump so that the flange of pump is aligned with aligning mark on front cover.

2. Make sure that "Z" marks are aligned.

EF-10

INJECTION PUMP

Installation and Adjustment (Cont'd) 3.

Install injection drive gear. ~: 69 - 69 N.m (6 - 7 kg-m, 43 - 61 ft-Ib) Make sure that the key does not fall into the front cover.

F EF159

=:;::;-SEF016A

PLUNGER LIFT ADJUSTMENT 1. Loosen injection pump mounting nuts and mounting bracket bolt. 2. Remove plug bolt from distributor head and install dial gauge. 3. Plunger lift measurement and adjustment. (1) Turn crankshaft counterclockwise 20 to 25 degrees from No.1 piston at T.O.C. (2) Find dial gauge's needle rest position at step (1) set position, then set the gaugeto zero. (3) Turn crankshaft clockwise until No.1 piston is set at T.O.C. (4) Read dial gauge indication. TD27: 0.632 - 0.672 mm (0.0249 - 0.0266 in) (equivalent to 6Â° B.T.D.C.) BD30: 1.20 - 1.24 mm (0.0472 - 0.0488 in) (equivalent to 6Â° B.T.D.C.) (5) If it is not within the above range, turn pump body until it comes within standard range. a. If indication is smaller than the specified value, turn pump body counterclockwise. b. If indication is larger than the specified value, turn pump body clockwise. 4. Tighten injection pump securely. Injection pump fixing bolt: ~: 20 - 26 N.m (2.0 - 2.6 kg-m, 14 - 18 ft-Ib) Injection pump to mounting bracket: ~: 26 - 36 N.m (2.6 - 3.6 kg-m, 19 - 26 ft-Ib) 5.

Disconnect dial gauge and reinstall plug bolt with new washer. ~: 14 - 20 N.m (1.4 - 2.0 kg-m, 10 - 14 ft-Ib) 6. Connect injection tubes. Flare nut: ~: 20 - 26 N.m (2.0 - 2.6 kg-m, 14 - 18 ft-Ib) 7. Bleed air from fuel system.

2 3 4 SEF852

EF-11

INJECTION PUMP Installation and Adjustment (Cont'd) IDLE AND MAXIMUM SPEED ADJUSTMENT Idle adjustment 1. Warm up engine. 2. Install tachometer after removing clamp. Idling speed: 700 rpm

3. 4.

Loosen accelerator wire adjusting nut. Make sure that idle adjusting screw and accelerator control lever contact each other. 5. Adjust idling speed by turning idle adjusting S(;,rew. 6. Tighten accelerator adjusting nut.

Maximum speed adjustment Maximum speed adjusting screw is retained by sealing wire and need not be adjusted under normal circumstances. However, if it becomes necessary to adjust it, the following procedure should be followed: 1. Start engine and warm it up until coolant temperature indicator points to middle of gauge. 2. Connect tachometer's pick-up to No.1 fuel injection tube. To obtain accurate reading of engine rpm, remove clamps that secure No.1 fuel injection tube. 3. Depress accelerator pedal fully under no load and, at this point, read the tachometer indication. Maximum engine speed (Under no load): 2,600 - 2,700 rpm

Sealing wire

4. If indication is lower than specified maximum engine speed,

Sealing cap

turn maximum speed adjusting screw counterclockwise 1 or 2 rotations. Then depress accelerator pedal to floor under no load and, at this point, read indication. 5. If indication is still lower than specified speed, repeat step 4 above until specified engine speed is reached. 6. After adjustment, tighten lock nut securely. 7. Seal with a sealing wire or install a sealing cap.

SEF5561

EF-12

INJECTION PUMP Disassembly PREPARATION • Before performing disassembly and adjustment, test the fuel injection pump and note test results. • Prior to beginning disassembly of fuel injection pump, clean all dust and dirt from its exterior. • Disconnect overflow valve and drain fuel. • Clean work bench completely, removing all foreign matter. • Collect only those service tools necessary for disassembling and reassembling. • Be careful not to bend or scratch any parts.

EF-13

INJ.ECTION PUMP Disassembly (Cont' d) Without high altitude compensator

CIl

; 5l Cl

"5CIl

> :0 E

51 II>

...

Il'i UI

C'i

.....

C 'i:

:S E u '"

Itl

8 ....

.. CIl

.s:: ...

'" :1:

., ~........

'0'"

- ....

0"':1

... ~~/~

o .

.......

":8 ~

SEF333F

EF-14

INJECTION PUMP Disassembly (Cont'd) With high altitude compensator

.. ..

ijj' N

_Gi

... ... N ,..:

,...'

10,

q q

,...

•

.. -..

t:iq

CJl;:

~ CJlN NN

.. Lti

..,...

E Z

:0 E

.. Q>

'"Q.

E :;,

N N

..,. ~'

:2 o .J::.

~'" ~ ..,

!ai '".. .. • Eo Q>

l:l

';:;

0 M

...., N

tIlO

.2N

"'>CJl :1:N

;;=0 "'N

8. E o

:;,

CJl

... Q>

'tl

~~ <.!!

'5'

i'" 8.

..E :;,

::E

..0

tIl

~'"

SEF384F

EF-15

INJECTION PUMP Disassembly (Cont'd) SPECIAL SERVICE TOOLS .

Block gauge (With high altitude compensator) KVl1229752

'<c~~:.~~~~3~, . 1;

Block gauge.fO. r "MS" adjustment .~ KVl1229110

8'O'k g'""

•

Dammy shaft ~ KVl1241920

(WI," high',,,.. d. oomp,"~,""

ft.

~ert

•

::\.

KVI1229762

device KVl1229072

.8-

Adjusting device KVl1229830

Adjusting device (For governor shaft) KVl1215842

Socket wrench IFor . regulating valve) ..KV11214260

Socket wrench (For delivery valve holder)----==z KVl1214110 (J.)

~ ~ ~

C0aJ

~ Socket :;:Ch ~ (For head plug) KVl1214250

Oil sealgUide (For drive shaft) KVl1222090

Feed pump holder KVl1229542

Socket wrench (For pivot bolt) KVl1214270 Dial gauge (For measuring plunger lift on car) KVl1229352

SEF5571

Remove pump cover.

With high altitude compensator (1) Remove nut, spring washer, spring seat and spring from control lever.

(2) Draw aligning marks on control lever and control shaft.

(3) Remove compensator cover.

EF-16

INJECTION PUMP Disassembly (Cont'd) (4) Remove bellows and adjusting shim.

(5) Remove E-ring, then remove spring seat and spring.

(6) Loosen nut.

(7) Remove governor cover plugs.

(8) Remove governor cover. a. Remove sealing wire and idle and maximum speed adjusting screws.

EF-17

INJECTION PUMP Disassembly (Cont'd) b. Remove governor cover fixing bolts and screws. Use hexagon wrench.

c. d.

Remove full-load adjusting screw. Remove governor cover, by holding control shaft with Tool (KV11229072) and lifting governor cover. Do not tap control shaft with a hammer.

(9) Remove high altitude compensator parts. a. Remove plugs. b. Remove lever pin and lever using a suitable drift and a plastic mallet, by tapping it from the right-hand side (viewed from the drive side).

Remove plug and pin.

d. Remove retainer, sleeveand washer. Use a suitable screwdriver to remove retainer.

EF-18

INJECTION PUMP Disassembly (Cont'd) e.

Remove nut and adjusting rod.

Remove bushing.

Without high altitude compensator (1) Remove nut, spring washer, spring seat and spring from control lever.

(2) Check aligning marks on control lever and control shaft.

(3) Remove pump cover. Lift and separate governor cover from control shaft, while holding control shaft with Tool (KV11229072). Do not tap control shaft with a hammer.

EF-19

INJECTION PUMP Disassembly (Cont'd) 2.

Remove control shaft from tension lever.

3. Remove governor shaftwith Tool (KV11215842). Loosen lock nut by turning it counterclockwise.

Remove governor sleeve, washer and flyweight, along with flyweight holder, then remove washer and shims.

Remove plug with special service tool.

EF-20

INJECTION

PUMP

DisasS$mbly (Cont'd) 6.

Remove delivery valve holder, spring, delivery valve and gasket. Distributor head has letters (A, B, C, D) stamped on it. Remove lettered parts in alphabetical order and arrange neatly.

SEF034A

7. Remove fuel-cut solenoid valve. Be careful not to drop the spring and armature.

8. Remove distributor head. Be careful not to drop the two support springs and guide pins.

9. Remove plunger assembly. Lift plunger, along with control sleeve,shim, spring seat, plunger spring, washer and shim.

10. Loosen left and right governor pivot bolts.

EF-21

INJECTIQN .PUMP Disassembly' (Cont' d) 11. Remove governor pivot bolts and lever assembly. Avoid pulling on start spring and start idle spring.

12. Remove shim, cam disc, spring and driving disc.

G;r--Shirn

earn disc

I--spring

Drivingdisc SEF478

13. Remove clip and pin.

14. Move adjusting pin to center of roller holder, as shown.

EF-22

INJECTION PUMP Disassembly (Cant'd) 15. Lift out roller holder with rollers without tilting. Be careful not to drop rollers.

16. Remove drive shaft. a. Rotate drive shaft until keyway faces the top of injection pump. b. Remove drive gear side key. c. Attach oil seal guide (KV11222090) onto drive shaft to prevent keyway from damaging oil seal. d. Be careful not to scratch inner surface of fuel injection pump body.

Be careful not to drop the key.

17. Remove speed,timer cover, O-rin~, shims, spring, piston and slider.

SEF513

18. Remove regulating valve with special service tool.

19. Loosen the two screws from feed pump cover.

EF-23

INJECTION PUMP

[ill

Disassembly (Cont'd) 20. Remove cover and feed pump assembly as a unit. 1) Insert feed pump holder (KV11229542) into fuel injection pump housing. 2) Turn injection pump upside down, as shown. 3) Remove cover and feed pump assembly as a unit. a. If cover and feed pump assembly are hard to remove or stuck midway, strike the pump body lightly. b. Do not change positions of vanes.

KV11229542

SEF487

Inspection 1. Wash all parts completely. 2. Replace worn or damaged parts. 3. Control edge of plunger must be sharp and contact surfaces must not exhibit any noticeable running tracks. If the condition is not good, replace plunger. 4. Check for height of all rollers. Difference in maximum and minimum roller height should be lessthan 0.02 mm (0.0008 in). SEF504

Assembly Always replace the following service parts as assembly units. • Distributor head, control sleeveand plunger • Feed pump assembly (pump impeller and vanes with eccentric ring) • Plunger spring kit • Roller assembly • Flyweight kit • Governor lever assembly

Larger side

Smaller side

"--. Feed pump cover

PREPARATION Dip all movable parts and O-rings in test oil, then clean. 1. Set feed pump cover, rotor with vanes, and ring on Tool (KV11229542). 1) Align the three holes in feed pump cover and ring. 2) Do not change positions of vanes. 3) Holes A and B in ring are not equally spaced to inner wall of ring.

SEF505

Install feed pump cover, rotor with vanes, and ring to pump housing. Be careful to install ring correctly. If left and right are reversed, fuel will not be discharged from feed pump.

SEF341F

EF-24

INJECTION PUMP

Assembly (Cont' d) When fuel injection pump rotates in direction "R" The. following description applies to fuel injection pumps that rotate in direction "R". 3. Turn fuel injection pump 180 and remove Tool (KVl1229542). Tighten screw to retain pump cover. a. When tightening screws, be careful not to scratch inner wall of pump housing. b. After tightening screws, make sure that rotor with vanes moves smoothly. 0

SEF507

4. Make sure that drive shaft and gear are assembled properly, as shown.

Applied grease ~

Side view of gear

[p::::c:[] 5.

Install drive shaft to housing while, key in drive shaft engages with key groove in rotor. a. Before installing drive shaft, attach oil seal guide (KV11222090) onto drive shaft. b. Be careful not to scratch oil sealsand inner wall of housing.

6. Set drive shaft's nail parallel to timer. 7. Install roller and holder. a. Do not interchange roller positions. If they are interchanged, refer to Inspection for correction. b. Make sure that washer is situated outward of rollers.

8. Align holder and timer adjusting pin holes.

EF-25

INJECTION, PUMP

Assembly (Cont' d) 9.

Install timer piston and slider as a unit.

a. Make sure that hole in slider faces towards roller holder. b. Make sure that concave hole in piston is on same side as return hole.

10. Insert timer adjusting pin into timer piston slider, and secure with retaining pin and clip.

Make sure that timer piston moves smoothly.

11. Install timer, using a 0.6 mm (0.024 in) thick shim, then install timer spring, shim, G-ring, and cover, in that order.

a. Use at least one shim on each side of timer spring. b. Use shims that were selected during bench test.

~~.~,m J

l\e~ in~~~

50"';

, ' ::;;;;

O-ri ng SEF513

12. Install regulating valve.

Be carefu I not to scratch O-rings.

13. Install driving disc with its concave side facing up.

EF-26

INJECTION PUMP

Assembly (Cont' d) 14. Measurement of plunger spring set length (dimension "KF") Dimension "KF" is the distance between the end face of the distributor barrel and the end face of the plunger. (1) Install distributor head, as shown. â&#x20AC;˘ Do not insert shim into" A" portion before measuring.

1 2 3 4 5 6 7 8 9

Spring seat Plunger spring Guide pin Distributor head Distributor barrel Spring seat Washer Shim Plunger SEF362F

(2) Set dial gauge so that it can cOQ1press0 to 10 mm (0 to 0.39 in), and reset to zero.

KV11229042 SEF419

(3) Apply force (not enough to compress plunger spring) to plunger's bottom in axial direction, and measure dimension "KF" with dial gauge, as shown.

(Shim is inserted,) SEF855

(4) Determine the shim to be used by calculating difference between standard and measured dimensions. Standard dimension "KF": Refer to S.O.S. [Example] When measured (dial gauge reading) value is 5.2 mm, 5.7 mm - 5.2 mm = 0.5 mm (shim thickness~o be used)

EF-27

INJECTION PUMP

Assembly (Cont~d) a. When there are no shims available of a thickness which matches specified dimensions, use slightly thicker shims. b. Use seleetedshim with distributor head in step 14-(3) above. c. Use the same size shim on each side of distributor head. d. Shims are available in seven different thicknesses. Part number

Thickness mm (in)

16882-V0700

0.5(0.020)

16882.V0701

0.8 (0.031)

16882-V0702

1.0 (0.039)

16882.V0703

1.2 (0.047)

16882-V0704

1.5 (0.059)

16882-V0705

1.8 (0.071)

16882-V0706

2.0 (0.079)

15. Adjustment of plunger dimensions ,(Measurement of dimension "K")

Dimension "K" is the distance from the end face of the distributor barrel to the end face of the plunger top, when the plunger is at the bottom dead center position. (1) Install parts as shown.

a. Do not install "spring" on driving disc. b. When inserting plunger and shim into cam disc, make sure that drive pin is situated in groove at bottom of plunger.

1 Drive shaft 2 Driving disc 3 Shim

4 Spring seat 5 Plunger spring 6 Guide pin

Spring seat

8 Shim 9 Distributor 10 Washer 11 Shim 12 eam disc

barrel

SEF370F

(2) Using a dial gauge, measure dimension as shown.

Rotate drive shaft so that plunger is set at bottom dead center. b. Securely mount distributor head with screws.

KV11229042

SEF044A

EF-28

INJECTION

PUMP

Assembly (Cont'd) (3) Determine shim to be used by calculating difference between measured (dial gauge reading) value and standard dimension "K", and position that shim on plunger's bottom.

"K": Refer to S.O.S.

SEF519

a. When measured value is greater than standard dimension "K", use a thicker shim. b. After shim has been positioned, measure dimension again to ensure that it is correct. c. Shims are available in 25 different thicknesses. Thickness mm (in)

Part number

16884.V0700

1.92 (0.0756)

16742.R8100

1.96 (0.0772)

16884.V0701

2.00 (0.0787)

16742.R8101

2.04 (0.0803)

16884.V0702

2.08 (0.0819)

16742.R8102

2.12 (0.0835)

16884.V0703

2.16 (0.0850)

16742.R8103

2.20 (0.0866)

16884.V0704

2.24 (0.0882)

16742.R8104

2.28 (0.0898)

16884. V0705

2.32 (0.0913)

16742.R8105

2.36 (0.0929)

16884. V0706

2.40 (0.0945)

16742-R8106

2.44 (0.0961)

16884. V0707

2.48 (0.0976)

16742.R8107

2.52 (0.09'92)

16884- V0708

2.56 (0.1008)

16742-R8108

2.60 (0.1024)

16884. V0709

2.64 (0.1039)

16742.R8109

2.68 (0.1055)

16884- V071 0

2.72 (0.1071)

16742-R8110

2.76 (0.1087)

16884.V0711

2.80 (0.1102)

16742-R8111

2.84 (0.1118)

16884.V0712

2.88 (0.1134)

Part number

Thickness mm (in)

--------- ---------

16. Install spring in top of driving disc, then install cam disc and shim.

Make sure cam disc drive pin and drive shaft key way face upwards.

EF-29

INJECTION PUMP Assembly (Con,l' d) 17. Install governor lever. Avoid pulling on start spring and start idle spring.

~ .

SEF521

,(~10.13N.m ~\r 11.0.1.3 kg-m. 7 - 9 ft.lb)

18. Install plunger assembly. a. Make sure control sleeve is installed facing spring seat side.

with

its small hole

Insert ball pin for governor lever into hole in control sleeve (shown by arrow).

19. Apply a coat of grease to guide pin, shim and spring seat, and attach these parts to distributor head.

20. a. b. c. d.

Install distributor head. Always face support spring toward governor lever. Be careful not to drop spring. Make sure that ball pin for governor lever is inserted properly into hole in control sleeve. After installing distributor head, make sure that plunger spring is at guide pin in spring seat.

EF-30

INJEC"FION PUMP Assembfy,(Cont'd) 21. Tighten distributor head. Distributor head bolts: ~: 10 - 14 N.m (1.0 -1.4 kg-m, 7 -10 ft-Ib)

22. Attach flyweight assembly. When installing governor shaft, be careful not to scratch O-rings.

Locknut~

--A~ -ring

Governor shaft ~~~Shim

~~ ~.~

l"---

Washer

Flyweight assembly

Shim

Governor

sleeve SE F5621

23. Adjust dimension "L". 1.5 - 2.0 mm (0.059 - 0.079 in) Lock nut: ~: 17.22 N.m (1.7 - 2.2 kg-m, 12 - 16 ft-Ib)

EF-31

INJECTI;QNPUMP

Assembly (Cont' d) 24. Measure axial play of flyweight holder. If it is not within specified range, adjust it by means of shims. ilL" : 0.15 - 0.35 mm (0.0059 - 0.0138 in) Shims are available in 5 different thicknesses.

Part number

Thickness mm (in)

19208-V0700

1.05 (0.0413)

19208- V0701

1.25 (0.0492)

19208. V0702

1.45 (0.0571)

19208-V0703

1.65 (0.0650)

19208-V0704

1.85 (0.0728)

25. Measurement of dimension "MS" amount of fuel injection)

(for determining starting

Dimensions "MS" is the distance between closing plug and start lever.

Collector lever

SEF856

(1) Remove lock (KV11215842).

SEF5611

EF-32

nut

and

governor

shaft

with

Tool

INJECTION PUMP

Assembly (Cont'd) (2) Install special service tool (dummy shaft) at governor shaft position.

(3) Install special service tool (dial gauge) with rod.

SEF049A

(4) Install special service tool (block gauge) to pump housing. KV11229752

is for pump with high altitude compensator.

KV11229110

is for pump without high altitude compensator.

SEF424A

SEF050A

(5) Push governor sleeve against flyweight. Hold governor sleeve in that position and set dial gaugeto zero.

EF-33

INUECTION Assetnbly(

PUMP

(;:ont' d)

(6) Push tension lever until it touches stopper pin. Back governor sleeve up until start lever touches tension lever. At this point read dial gauge. MS: Refer to S.O.S.

Locking cap

Push

(7) If dial gauge indication is not within this range, replace closing plug and adjust dimension "MS" to that range. Closing plugs are available in 8 different lengths.

.....•.•.•.••.• CI"~Jl SEF538

Part number

Length mm (in)

16268-R8100

3.10 (0.1220)

16268-R8101

3.30 (0.1299)

16268-R8102

3.50 (0.1378)

16268-R8103

3.70 (0.1457)

16268-R8104

3.90 (0.1535)

16268-R8105

4.10 (0.1614)

16268-R8106

4.30 (0.1693)

16268-R8107

4.50 (0.1772)

26. Install control lever shaft. Apply a coat of greaseto lever shaft end. 27. InstaII governor cover.

With high altitude compensator (1) Position adjusting rod bushing so that its height above upper surface of governor cover is with in specified range. L: 20.5:tO.5 mm (O.807:tO.020 in) Ensure that holes in adjusting rod bushing and governor cover are aligned properly.

EF-34

INJECTION PUMP

CY!J

Assembly (Cont'd) (2) Install adjusting rod. (3) Install washer and nut. (4) Tighten nut. Adjusting rod bushing lock nut: ~: 25 - 34 N.m (2.5 - 3.5kg-m, 18 - 25 ft-Ib) a. Prevent adjusting rod bushing from rotating by locking its nut. b. If nut and bushing rotate together, bushing height above upper surface of governor cover is insufficient. (5) Install washer, sleeve and retainer.

(6) Install pin. Ensure that pin moves smoothly when adjusting rod is moved up or down.

(7) Install lever. Use a suitable bar as a guide to properly install lever.

EF-35

INJECTION PUMP Assembly (Cont'd) Ensure that lever moves smoothly when adjusting rod is moved up or down.

(8) Check clearance between block gauge and lever. If not within specifications, change the pin. Clearance:

0.1 mm (0.004 in) Pin Part number

Length mm (in)

19276-02NOO

24.6 (0.969)

19276-02N01

24.8 (0.976)

19276-02N02

25.0 (0.984)

19276-02N03

25.2 (0.992)

19276-02N04

25.4 (1.000)

(9) InstaII governor cover.

(10) Install control lever. Align aligning marks of speed control shaft.

EF-36

lever and control lever

INJECTION PUMP Assembly (Cont'd) (11) Install spring seat, spring and E-ring. (12) Install adjusting shim and bellows. (13) Install compensator cover.

I (

SEF438A

Without high altitude compensator (1) Install pump governor cover.

(2) Install speed control lever assembly. Align aligning marks of speed control lever and control lever shaft.

28. Install plug with new G-ring. Always replace plug with a new one. Plug: ~: 59 - 78 N.m (6.0 - 8.0 kg-m, 43 - 58 ft-Ib) 29. Install plug bolt with a new gasket.

SEF055A

~44

.54 N'm (4.5 . 5.5 kg.m, 33 - 40 ft-Ib)

30. 31. a. b.

Install fuel cut solenoid valve. Install del ivery valve. Always usenew washers. Make sure that delivery valve is reinstalled in its original position.

EF-37

INJECTION PUMP Test PREPARATION Nozzle

KV11257800

Nozzle holder

KV11257802 kPa (bar, kg/cm2,

Nozzle starting pressure

psi)

14,711 -15,201

Nozzle tube Inner dia. x outer dia. x length

kPa (bar, kg/cm2

psi)

- 2,204)

20 (0.20, 0.2, 2.8) ISO 4113 or SAE Standard Test Oil (SAE J967d)

Fuel (test oil) Fuel temperature

150 -155,2,133

KV11205032 2.0 x 6.0 x 840 (0.079 x 0.236 x 33.07)

mm (in) Fuel feed pressure

(147.1 -152.0,

Â°c (OF)

45 . 50 (113 - 122)

Rotating direction

Right (observed from the drive shaft)

Injection sequence

1-3-4-2

1. Prepare necessaryservice tools. Insert device ~ KVl1229522

M U

Nozzle holder KVl1257802

Injection pipe KVl1205032

Measuring device for pump timer stroke KVl1282815

SEF057A

2. Pour test oil into fuel injection pump. Test oil should be ISO 4113, SAE Standard Test Oil (SAE J967d) or its equivalent.

SEF950

EF-38

INJECTION PUMP Test (Cant'd) 3. Install fuel injection pump to pump tester. 4. Connect necessarypiping.

1 Fuel supply inlet from pump tester 2 Overflow valve 3 Coupling 4 Fixing stand SEF378F

5. Make sure that governor shaft is properly installed. Adjust dimension "L".

~,""'h'"

ilL ": 1.5 - 2.0 mm (0.059.0.079 in) Governor shaft lock nut: ~ : 17 - 22 N.m (1.7.2.2 kg-m, 12 .16 ft-Ib)

. SEF500

8.9mm (0.31 - 0.35 in)

L Maximum speed adjusting screw SEF569

6. Run fuel injection pump as follows: (1) Maintain test oil in tank at 45 to 50Â°C (113 to 122Â°F). (2) Set control lever at "full speed" using a spring. Set maximum speed adjusting screw in position shown, by turn. ing it counterclockwise. (3) Furnish specified voltage of 12 volts to fuel-cut solenoid valve to activate it. (4) Rotate fuel injection pump by hand to see if it moves smoothly. (5) Rotate fuel injection pump at 300 rpm to make sure that all air inside pump chamber is discharged through overflow valve. (6) Set feed oil pressure at 20 kPa (0.20 bar, 0.2 kg/cm2, 2.8 psi). (7) Run fuel injection pump at 1,000 rpm for ten minutes. If fuel leakage, fuel injection failure or unusual noise is noticed, immediately stop pump tester operation and check fuel injection pump for abnormalities.

EF-39

INJECTION PUMP

Test (Cont'd) ADJUSTMENT Preadjust full-load delivery If equipped with high altitude compensator, remove high altitude compensator cover, bellows and adjusting shim. 1. Set control lever at "full speed" using a spring. Set maximum speed adjusting screw in position shown, by turning it counterclockwise. Refer to step 6-(2) in Preparation. 2. Furnish specified voltage of 12 volts to activate fuel-cut solenoid valve. 3. Rotate fuel injection pump at 1,100 rpm, and measure amount of fuel injection. Standard fuel injection: Refer to S.O.S.

Full-load adjusting screw

If fuel injection is less than standard, adjust it with fu II-load adjusting screw. Turn adjusting screw clockwise to increase fuel injection.

Adjustment of feed pump pressure 1. Repeat steps 1 and 2 outlined under "Preadjust Full-Load Delivery" heading. 2. Measure feed pump pressure at specified fuel injection pump rpm. Standard fuel injection:

Refer to S.O.S.

a. When measured pressure is lower than specifications. Push in plug that is driven into regulating valve body. Be careful not to push plug in too far.

EF-40

INJECTION PUMP

Test (Cont'd) b. When measured pressure is higher than specifications.

(1) Remove regulating valve from fuel injection pump, and disassemble regulating valve using Tool (KV11229462).

Spring-. Piston

-0

Spring---ring

SEF572

(2) Drive plug out until it is flush with end face of regulating valve. Install spring, piston and spring ring, in that order, to regu lating valve. Make sure that spring ring is flush with end face of regulating valve body when it is pushed in.

Plug

SEF573

(3) Attach regulating valve to fuel injection pump. Regulating valve: ~: 10 - 13 N.m (1.0 - 1.3 kg.m, 7 - 9 ft-Ib) (4) Adjust supply pump pressure to specifications. Refer to step

2-a. Spring ring Regulating valve

SEF637

Adjustment of speed timer 1. Repeat steps 1 and 2 outlined under "Preadjust Full-Load Delivery" heading. 2. Remove cover from high-pressure side (side without spring) of timer, and attach Tool (KV11282815) to that side.

3. Measure timer piston strokes at specified fuel injection pump rpm indicated below. Standard fuel injection: Refer to S.O.S.

EF-41

INJECTION PUMP

Test (Cont'd) 4.

If timer piston stroke is not within specified range, remove cover from low-pressure side of timer and adjust piston stroke by adding shim(sl.

a. Shims (service parts) Part number

Thickness mm (in)

16880-V0700

0.6 (0.024)

16880-V0701

0.7 (0.028)

16880-V0702

0.9 (0.035)

16880-V0703

1.0 (0.039)

16880-V0704

1.2 (0.047)

b. Make sure that at least one shim is used on each side of timer spring.

Adjustment of fuel injection under full-load 1. Set control lever at "full speed" using a spring. 2. Furnish specified voltage of 12 volts to activate fuel-cut solenoid valve. 3. Measure fuel injection at each specified fuel injection pump rpm. Standard fuel injection: Refer to S.O.S.

4. If fuel injection is not within standard range, adjust it using full-load adjusting screw.

Adjustment of fuel injection during idle 1. Pull spring until control lever touches idle speed adjusting screw. 2. Furnish specified voltage of 12 volts to activate fuel-cut solenoid valve. 3. Measure fuel injection at specified fuel injection pump rpm. Standard fuel injection: Refer to S.O.S.

EF-42

INJECTION PUMP

Test (Cont'd) 4.

Idle speed adjusting screw

If fuel injection is not within specified range, adjust using idle speed adjusting screw.

a. Tightening this screw will increase fuel injection amount. b. Make sure that control lever angle (a) is set at the specified range. a: Refer to S.O.S. If control lever angle is not within specified range, adjust it by repositioning control lever on control shaft. (One serration pitch: 15Â°) After control lever has been repositioned, be sure to measure amount of fuel injection at idle speed again. SEF379F

Adjustment of fuel injection during start 1. Set control lever at "fu II speed" by pu lling spring. 2. Furnish specified voltage of 12 volts to activate fuel-cut solenoid valve. 3. Measure fuel injection at specified fuel injection pump rpm. Standard fuel injection: Refer to S.O.S. 4.

If fuel injection is lower than standard, check, "MS" dimension. Refer to step 25 for Injection Pump Assembly.

Adjustment of fuel injection at maximum pump rpm 1. Set control lever at "full speed" by pulling spring. 2. Furnish specified voltage of 12 volts to activate fuel-cut solenoid valve. 3. Measure fuel injection at specified fuel injection rpm. Standard fuel injection: Refer to S.O.S.

If fuel injection is not within standard range, adjust using maximum speed adjusting screw.

EF-43

INJECTION PUMP Test (Cant'd) a. Tightening screw will decreasefuel injection. b. Make sure that control lever angle (/3) is within the specified range. /3: Refer to S.O.S.

Measurement of overflow amount 1. Set control lever at "full speed" by pulling spring. 2. Furnish specified voltage of 12 volts to activate fuel cut solenoid valve. 3. Measure fuel overflow at specified fuel injection rpm. Fuel overflow: Refer to S.O.S.

Operation check .of fuel-cut solenoid valve When engine is idling and fuel cut solenoid valve current is OF F, be sure there is no injection. This check has to be done for approx. 5 seconds.

EF-44

INJECTION NOZZLE Removal and Installation 1. Remove injection tube assembly. 2. Remove spill tube assembly. To prevent spill tube from breaking, remove it by gripping nozzle holder.

3. 4.

Remove injection nozzle assembly using deep socket wrench. Install injection nozzle in the reverseorder of removal. Injection nozzle to cylinder head: ~: 54-64 N.m (5.5 - 6.5 kg-m, 40 - 47 ft-Ib) Nozzle support bolt (B030): ~: 44.49 N.m (4.5 - 5.0 kg-m, 33 - 36 ft-Ib) Spill tube nut: ~: 29 - 39 N.m (3.0 . 4.0 kg-m, 22 . 29 ft-Ib) Injection tube flare nut: ~: 20-25 N.m (2.0. 2.5 kg-m, 14 - 18 ft-Ib) a. Nozzle gaskets should always be replaced. b. To prevent spill tube from breaking later, spill tube nuts should be tightened gradually in sequence. 5. Bleed air from fuel system. Refer to BLEEDING FUEL SYSTEM.

EF-45

I NJECTION

NOZZLE

Disassembly 1. Loosen inlet connector turning.

keeping nozzle top

from

2. Arrange all disassembled parts in order shown at left.

Inlet connector Adjusting shim, N~zzle Spring~\ Spring seat ~

while

',~

spacer~~ Nozzle~, needle

~ ~~-

"lf1 ~ V'

Nozzle body Nozzle holder Nozzle washer Nozzle gasket

Nozzle } assembly

SEF425F

8030

Pin Nozzle needle Nozzle assembly Retaining ~29 - 39 N.m nut (3.0 - 4.0 kg-m, 22 - 29 ft-lbJ SEF843M

Inspection Thoroughly clean all disassembled parts with fresh kerosene or solvent. • If nozzle needle is damaged or fused, replace nozzle assembly with a new one. • If end of nozzle needle is seized or excessively discolored, replace nozzle assembly. • Check nozzle body and distance piece for proper contact. If excessively worn or damaged, replace nozzle assembly or nozzle holder assembly. • Check distance piece and nozzle holder for proper contact. If excessively worn or damaged, replace nozzle holder assembly. • Check nozzle spring for excessive wear or damage. If excessively worn or damaged, replace nozzle holder assembly.

EF-46

INJECTION NOZZLE Cleaning 1. Clean nozzle assembly using the Nozzle Cleaning Kit.

2. Portions which should be cleaned are indicated in the left figure.

T027 Adjusting shim

In let con nector

Nozzle holder

Nozzle spring

~Nozzle needle Nozzle body

SEF426F

8030

Adjusting shim Nozzle spring Spring seat Spacer Nozzle needle Nozzle assembly Retaining nut

Remove any carbon from exterior of nozzle body (except wrapping angle portion) by using Tool.

EF-47

INJECTiON NOZZLE Cleaning (Cont'd) 4. Clean fuel sump of nozzle body using Tool.

T027

KV11290632

SEF831

8030 KV11290122

SEF6391

5. Clean nozzle seat by using Tool. This job should be performed with extra precautions, since efficiency of nozzle depends greatly on a good nozzle seat.

T027

SEF832

8030

KV11290150

Cleaning area SEF6401

6. Clean spray hole of nozzle body by using Tool. To prevent spray hole from canting, always clean it by starting with inner side and working towards outside.

T027

KVl1290220

SEF833

EF-48

INJECTION NOZZLE Cleaning (Cont'd)

Decarbon nozzle needle tip by using Tool.

8. Check needle for proper position. (1) Pull needle about halfway out from body and then release it. (2) Needle should sink into body very smoothly from just its own weight. (3) Repeat this test and rotate needle slightly each time. If needle fails to sink smoothly from any position, replace both needle and body as a unit.

TD27

SEF835

SEF641 I

EF-49

INJECTION

NOZZLE

Assembly Assemble in the reverse order of disassembly. Inlet connector to nozzle holder (TD27): A: 34 - 54 N.m (3.5 - 5.5 kg-m, 25 - 40 ft-Ib) Retaining nut to nozzle holder (BD30): toJ: 29 - 39 N.m (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)

KVl1292210

If{ SEF967

Test and Adjustment WARNING: When using nozzle tester, be careful not to allow fuel sprayed from nozzle to come into contact with your hand or body, and make sure that your eyes are properly protected with goggles.

INJECTION PRESSURE TEST 1. Install nozzle to injection nozzle tester and bleed air from flare nut.

EF791A

2. Pump the tester handle slowly (one time per second) and watch the pressure gauge. 3. Read the pressure gauge when the injection pressure just starts dropping. Initial injection pressure: Unit:

kPa (bar, kg/cm2,

TD27

8D30

Used

9,807 (98.1, 100, 1,422)

15,691 (156.9, 160,2,275)

New

10,297 - 11,278 (103.0 - 112.8, 105 - 115, 1,493 - 1,635)

psi)

16,182 - 17,162 (161.8-171.6,165-175, 2,346 - 2,489)

New nozzle is required to always check initial injection pressure.

EF-50

INJECTION NOZZLE Test and Adjustment (Cont'd)

Adjusting shim

SEF427F

4. To adjust injection pressure, change adjusting shims. a. Increasing the thickness of adjusting shims increases initial injection pressure. Decreasing thickness reduces initial pressure. b. A shim thickness of 0.04 mm (0.0016 in) corresponds approximately to a difference of 471 kPa (4.71 bar, 4.8 kg/cm2 , 68 psi) in initial injection pressure. (TD27) c. A shim thickness of 0.010 mm (0.0004 in) corresponds approximately to a difference of 147 kPa (1.47 bar, 1.5 kg/cm2 , 21 psi) in initial injection pressure. (8030) Thickness

TD27 0.1 0.2

mm (in) 8030

(0.004) (0.008)

0.3

(0.012)

0.4 0.5 0.52 0.54 0.56 0.58 0.8

(0.016) (0.020) (0.0205) (0.0213) (0.0220) (0.0228) (0.031)

0.5 (0.020) to 1.5 (0.059) [Every 0.025 (0.0010)]

LEAKAGE TEST 1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6 bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection pressure. 2. Check that there is no dripping from the nozzle tip or around the body. 3. If there is leakage, clean, overhaul injection nozzle or replace it. Faulty

Good

SEF674A

SPRAY PATTERN TEST

TD27

.. .

â&#x20AC;˘

1. Pump the tester handle one time per second. 2. Check the spray pattern. 3. If the spray pattern is not correct, clean injection nozzle or replace it .

Good

Wrong EF794A

EF-51

INJECTION NOZZLE Test and Adjustment (Cont'd) 8030

Good

>Wrong

FEF.156

EF-52

BLEEDING FUEL SYSTEM Bleeding Fuel System (Engine on vehicle) Air should

be bled out of fuel system wh~n injection pump is

removed or fuel system is repaired. Protect pump and engine mounts from fuel splash with rags. If engine will not start after bleeding air, loosen injection tubes at nozzle side and crank engine until fuel overflows from injection tube. Tighten injection tube flare nutS.

If the engine does not operate smoothly after it has started, race it two or three times. WITHOUT

Up and down

AIR

VENT

SCREW

Method A

Move the priming pump up and down until there is suddenly more resistance in the movement.

SEF429F

Method B

1. Loosen injection pump bleeder screw/or disconnect return hose and priming. 2. Make sure that fuel overflows at bleeder screw/tube end, then tighten it/connect hose.

SEF958

WITH

Up and down

AIR

VENT

SCREW

Method A

1. Loosen the air vent screw CD. 2. Move the priming pump @ up and down until no further airbleed comes out of the air vent screw CD . 3. Tighten the air vent screw CD. 4. Move the priming pump @ up and down until there is suddenly more resistance in the movement. SEF430F

Method B

Up and down

1. Loosen the air vent screw CD. 2. Move the priming pump @ up and down until no further airbleed comes out of the air vent screw CD. 3. Tighten the air vent screw CD.

SEF431 F

EF-53

BLEEDING FUEL SYSTEM Bleeding Fuel System (Engine on vehicle) (Cont'd) 4. PUSh~ fI------... Fuel filter

Loosen injection pump bleeder screw/or disconnect return hose and priming. 5. Make sure that fuel overflows at bleeder screw/tube end, then tighten it/connect hose.

SEF958

Checking Priming Pump Before checking priming pump, make sure that fuel filter is filled with fuel. 1. Disconnect fuel return hose. Place a suitable container beneath hose end. 2. Pump priming pump and check that the fuel overflows from the hose end. If not, replace priming pump.

EF-54

SPECIAL ..SERVICE. TOOLS Injection Pump ADJUSTING

DEVICE ON CAR

Tool number Tool name

Description

KVl1229352 Measuring device (Set length of plunger spring)

G) @

CID

KVl1229350 Holder KV 11229360 Nut KV 11229370

KVl1254410 Dial gauge

DISASSEMBLING G) @

CID

AND ASSEMBLlNG TOOLS

KVl1244852 Universal vise KVl1244872 Bracket KVl1244792 Bracket

KV11229072 Insert device

KVl1214110 Socket wrench for delivery valve

I(Vl1214270 Socket wrench for governor pivot bolt

EF-55

SPECIAL SERVICE TOOLS Injection Pump (Cont'd) Tool number Tool name

Description

KV11214260 Socket wrench for regulating valve

g D

KV11214250 Socket wrench for distributor head plug

KV11215842 Governor shaft adjusting device

KV11229542 Feed pump holder

"MS" measuring device set

KV11229110 Block gauge

@ KV11241920 Dummy shaft

@ KV11229830 Rod

KV11229752 Block gauge (For high altitude compensator)

KV11229762 Block gauge (For high altitude compensator)

KV11229042 "K" & "KF" measuring device

KV11222090 Oil seal guide (For drive shaft)

EF-56

SPECIAL SERVICE TOOLS Injection Pump (Cont'd) ADJUSTING

DEVICE ON PUMP TESTER

Tool number Tool name

0"";0';0"

KVl1281036 Fixing stand

~ KVl1242442 Coupling

~ KVl1282815 Measuring device (Timer advance angle)

KVl1205032 Injection pipe [840 mm (33.07 in)]

({l

KVl1229462 Extractor (Disassembling of regulating valve)

KVl1229522 Insert device (Assembling of regulating valve)

KVl1257802 Nozzle holder (Bosch type EF8511.9A)

KVl1257800 Nozzle (Bosch type DN12SD12T)

ADJUSTING

t1 DEVICE

FOR POTENTIOMETER

KVl1229882 Voltage check harness (F or potentiometer)

KVl1244582 Voltage adjusting harness (F or potentiometer)

EF-57