Manual Cuminn 6bta

SEBM010019
DIESEL ENGINE
fl This Shop Manual is made by adding the special descriptions for the 102E-2 series to the
Shop Manual for the current 102E-1 series.
© 2004 1
All Rights Reserved 00-1
Printed in Japan 05-04(02) (19)
The affected pages are indicated by the use of the
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following marks. It is requested that necessary
actions be taken to these pages according to the
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Pages having no marks are those previously re-

vised or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
b 00-1 (19) 01-5-2 (12) 01-22-4 (12) 11-5-1 (12) 11-31

00-2 (2) 01-6 (12) 01-23 (12) 11-5-2 (12) 11-32 (15)
b 00-2-1 (19) 01-7 (12) 01-24 (12) 11-5-3 (12) 11-33 (12)
b 00-2-2 (19) 01-7-1 (12) 01-25 (12) 11-5-4 (12) 11-33-1 (12)
b 00-2-3 (19) 01-7-2 (12) 01-26 (12) 11-5-5 (15) 11-33-2 (15)
b 00-2-4 (19) 01-7-3 (12) 01-27 (12) 11-5-6 (15) 11-34 (13)
00-3 01-7-5 (12) 01-27-1 (12) 11-5-7 (15) 11-35 (13)
00-4 01-7-6 (12) 01-28 (12) 11-6 (12) 11-36 (13)
00-5 b 01-7-7 (19) 01-29 (12) 11-7 (12) 11-37
00-6 b 01-7-8 (19) 01-30 (12) 11-7-1 (12) 11-38 (12)
00-7 01-7-9 (18) 01-31 (12) 11-8 (10) 11-40 (12)
00-8 b 01-7-10 (19) 01-32 (12) 11-9 (13) 11-41 (10)
00-9 b 01-7-11 (19) 01-33 (12) 11-10 (12) 11-41-1 (12)
00-10 01-8 (12) 01-34 (12) 11-11 11-42 (12)
00-11 01-9 (12) 01-34-1 (12) 11-11-1 (12) 11-43 (12)
00-12 01-10 (12) 01-34-2 (12) 11-11-2 (10) 11-44 (13)
00-13 01-11 (12) 01-34-3 (12) 11-11-3 (10) 11-45 (12)
00-14 01-12 (12) 01-34-5 (12) 11-11-4 (10) 11-45-1 (12)
00-15 01-13 (12) 01-34-6 (12) 11-12 (15) 11-45-2 (12)
00-16 01-14 (12) 01-34-8 (12) 11-14 (17) 11-45-3 (12)
00-17 01-15 (12) c 01-34-18 (19) 11-15 11-45-4 (10)
00-18 01-16 (12) c 01-34-19 (19) 11-15-1 (17) 11-46
00-19 01-17 (12) 01-34-20 (10) 11-15-2 (10) 11-47 (13)
00-20 01-18 (12) 01-34-21 (13) 11-16 (15) 11-48 (12)
00-21 01-19 (12) c 01-34-22 (19) 11-18 (17) 11-49 (10)
00-22 01-19-1 (15) 01-34-31 (13) 11-19 (10) 11-49-1 (12)
00-23 (12) 01-19-2 (15) 01-34-32 (13) 11-19-1 (17) 11-49-2 (10)
00-24 (13) 01-19-3 (15) 01-34-33 (18) 11-19-2 (10) 11-50
00-25 (13) 01-19-4 (15) b 01-34-34 (19) 11-20 (15) 11-51
00-26 (12) 01-19-5 (15) 01-34-35 (15) 11-21 (15) 11-52
00-27 (6) 01-19-6 (15) 01-34-36 (15) 11-22 (12) 11-53
00-28 (13) 01-19-7 (15) b 01-34-37 (19) 11-23 (12) 11-55 (12)
01-19-8 (15) b 01-34-38 (19) 11-24 (12) 11-55-1 (12)
01-1 (10) 01-20 (6) 01-35 (12) 11-25 (12) 11-55-2 (12)
01-1-1 (12) 01-21 (6) 01-36 (12) 11-26 (12) 11-56 (15)
b 01-1-2 (19) 01-21-1 (15) 11-26-1 (12) 11-57 (10)
01-2 (10) b 01-21-2 (19) 11-1 11-27 (17) 11-58
01-3 (12) 01-22 (12) 11-2 (12) 11-28 (12) 11-59 (15)
01-4 (12) 01-22-1 (12) 11-3 (12) 11-29 (12) 11-59-1 (12)
01-5 (12) 01-22-2 (12) 11-4 (12) 11-29-1 (12) b 11-59-2 (19)
01-5-1 (12) 01-22-3 (12) 11-5 11-30 (12) 11-59-3 (12)
102 SERIES 00-2-1

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11-60 (13) 12-38 (15) c 12-50-69 (19) 12-74 (10) 12-127 (10)
11-61 12-39 (15) b 12-50-70 (19) 12-75 (1) 12-128 (1)
11-62 (13) 12-40 (15) 12-50-71 (12) 12-76 (1) 12-129 (1)
11-63 (13) 12-41 (15) 12-50-72 (12) 12-77 (1) 12-201 (6)
11-64 (15) 12-42 (15) 12-50-73 (15) 12-78 (1) 12-202 (10)
b 11-64-1 (19) 12-43 (15) b 12-50-74 (19) 12-79 (1) 12-203 (12)
b 11-64-2 (19) 12-44 (15) 12-50-75 (18) 12-80 (1) 12-204 (12)
b 11-64-3 (19) 12-49 (12) b 12-50-76 (19) 12-81 (1) 12-205 (12)
b 11-64-4 (19) 12-49-1 (12) b 12-50-77 (19) 12-82 (1) 12-206 (12)
b 11-64-5 (19) b 12-49-2 (19) 12-51 (12) 12-83 (1) 12-206-1 (12)
b 11-64-6 (19) 12-50 (12) 12-51-1 (12) 12-84 (1) 12-206-2 (12)
11-65 (15) 12-50-1 (12) 12-51-2 (12) 12-85 (1) 12-207 (12)
b 11-66 (19) 12-50-2 (12) 12-51-3 (12) 12-86 (1) 12-208 (12)
b 11-66-1 (19) 12-50-3 (12) b 12-51-10 (19) 12-87 (1) 12-209 (12)
11-67 (10) 12-50-4 (12) c 12-51-11 (19) 12-88 (1) 12-210 (12)
12-50-5 (12) 12-52 (14) 12-89 (1) 12-211 (12)
12-1 (15) 12-50-6 (12) 12-53 (17) 12-90 (1) 12-212 (12)
12-2 (6) 12-50-7 (12) 12-53-1 (17) 12-91 (1) 12-213 (10)
12-3 (12) 12-50-8 (12) 12-53-2 (17) 12-92 (1) b 12-220 (19)
12-4 (15) 12-50-9 (12) 12-53-3 (17) 12-93 (1) b 12-221 (19)
12-5 (15) 12-50-10 (12) 12-53-4 (17) 12-94 (1) c 12-221-1 (19)
12-6 (15) 12-50-11 (12) 12-53-5 (17) 12-95 (1) c 12-221-2 (19)
12-7 (15) 12-50-12 (12) 12-53-6 (17) 12-96 (1) b 12-222 (19)
12-8 (15) 12-50-13 (12) 12-53-7 (17) 12-97 (1) b 12-223 (19)
12-9 (12) 12-50-14 (12) 12-53-8 (17) 12-98 (1) 12-251 (1)
12-10 (12) 12-50-15 (12) 12-53-9 (17) 12-99 (1) 12-252 (1)
12-11 (15) 12-50-16 (12) 12-53-10 (17) 12-100 (1) 12-253 (1)
12-12 (15) 12-50-17 (12) b 12-53-21 (19) 12-101 (1) 12-254 (1)
12-13 (15) 12-50-18 (12) b 12-53-22 (19) 12-102 (1) 12-255 (1)
12-14 (15) 12-50-19 (12) b 12-53-23 (19) 12-103 (1) 12-256 (17)
12-15 (15) 12-50-20 (12) b 12-53-24 (19) 12-104 (1) 12-257 (17)
12-16 (15) 12-50-21 (12) b 12-53-25 (19) 12-105 (1) 12-258 (10)
12-17 (15) 12-50-22 (12) 12-53-26 (17) 12-106 (1) 12-259 (10)
12-18 (15) 12-50-23 (12) 12-54 (10) 12-107 (1) 12-260 (10)
12-19 (15) 12-50-24 (12) 12-55 (1) 12-108 (1) 12-261 (10)
12-20 (15) 12-50-25 (12) 12-56 (1) 12-109 (1) 12-262 (10)
12-21 (15) 12-50-26 (12) 12-57 (1) 12-110 (1) 12-263 (10)
12-22 (15) 12-50-27 (12) 12-58 (1) 12-111 (1) 12-264 (10)
12-23 (15) 12-50-28 (12) 12-59 (1) 12-112 (10) b 12-265 (19)
12-24 (15) 12-50-29 (12) 12-60 (10) 12-113 (10) 12-266 (10)
12-25 (15) 12-50-30 (12) 12-61 (1) 12-114 (1) 12-267 (10)
12-26 (15) 12-50-31 (12) 12-62 (10) 12-115 (1) 12-268 (1)
12-27 (15) 12-50-32 (12) 12-63 (10) 12-116 (1) 12-269 (12)
12-28 (15) 12-50-33 (12) 12-64 (1) 12-117 (1) 12-270 (10)
12-29 (15) 12-50-34 (12) 12-65 (1) 12-118 (1) 12-271 (10)
12-30 (15) 12-50-35 (12) 12-66 (1) 12-119 (1) 12-272 (10)
12-31 (15) 12-50-36 (12) 12-67 (1) 12-120 (1) 12-273 (10)
12-32 (15) 12-50-40 (12) 12-68 (1) 12-121 (1) 12-274 (10)
12-33 (15) 12-50-41 (12) 12-69 (1) 12-122 (1)
12-34 (15) 12-50-51 (12) 12-70 (1) 12-123 (1) 13-1 (2)
12-35 (15) 12-50-52 (12) 12-71 (1) 12-124 (1) 13-2 (2)
12-36 (15) c 12-50-67 (19) 12-72 (1) 12-125 (1) 13-3 (2)
12-37 (15) c 12-50-68 (19) 12-73 (10) 12-126 (10) 13-4 (2)
00-2-2 102 SERIES

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13-5 (2) 13-58 (2) 13-110 (2) 13-163 (2) 13-215 (2)
13-6 (2) 13-59 (2) 13-111 (2) 13-164 (10) 13-216 (10)
13-7 (2) 13-60 (10) 13-112 (2) 13-164-1 (10) 13-217 (2)
13-8 (2) 13-61 (2) 13-113 (2) 13-165 (2) 13-218 (10)
13-9 (2) 13-62 (2) 13-114 (10) 13-166 (2) 13-219 (10)
13-10 (2) 13-63 (2) 13-115 (2) 13-167 (2) 13-220 (2)
13-11 (2) 13-64 (2) 13-116 (10) 13-168 (2) 13-221 (2)
13-12 (2) 13-65 (2) 13-117 (2) 13-169 (2) 13-222 (2)
13-13 (2) 13-66 (2) 13-118 (2) 13-170 (2) 13-223 (10)
13-14 (2) 13-67 (10) 13-119 (2) 13-171 (2) 13-224 (2)
13-15 (2) 13-68 (10) 13-120 (2) 13-172 (2) 13-225 (2)
13-16 (2) 13-68-1 (10) 13-121 (2) 13-173 (2) 13-226 (10)
13-17 (2) 13-69 (2) 13-122 (2) 13-174 (2) 13-227 (2)
13-18 (2) 13-70 (2) 13-123 (10) 13-175 (2) 13-228 (10)
13-19 (2) 13-71 (2) 13-124 (2) 13-176 (2) 13-229 (2)
13-20 (2) 13-72 (10) 13-125 (2) 13-177 (2) 13-230 (2)
13-21 (2) 13-73 (2) 13-126 (2) 13-178 (2) 13-231 (2)
13-22 (2) 13-74 (2) 13-127 (2) 13-179 (2) 13-232 (2)
13-23 (2) 13-75 (2) 13-128 (2) 13-180 (2) 13-233 (10)
13-24 (2) 13-76 (2) 13-129 (2) 13-181 (2) 13-234 (2)
13-25 (2) 13-77 (2) 13-130 (2) 13-182 (2) 13-235 (2)
13-26 (2) 13-78 (2) 13-131 (2) 13-183 (2) 13-236 (10)
13-27 (2) 13-79 (2) 13-132 (2) 13-184 (2) 13-237 (10)
13-28 (10) 13-80 (2) 13-133 (2) 13-185 (2) 13-238 (2)
13-29 (2) 13-81 (2) 13-134 (2) 13-186 (2) 13-239 (10)
13-30 (10) 13-82 (2) 13-135 (2) 13-187 (2) 13-240 (10)
13-31 (2) 13-83 (2) 13-136 (2) 13-188 (2) 13-241 (10)
13-32 (2) 13-84 (2) 13-137 (2) 13-189 (2) 13-242 (2)
13-33 (2) 13-85 (2) 13-138 (2) 13-190 (2) 13-243 (2)
13-34 (2) 13-86 (2) 13-139 (2) 13-191 (2) 13-244 (2)
13-35 (2) 13-87 (2) 13-140 (2) 13-192 (2) 13-245 (2)
13-36 (2) 13-88 (10) 13-141 (2) 13-193 (2) 13-246 (2)
13-37 (2) 13-89 (10) 13-142 (2) 13-194 (2) 13-247 (2)
13-38 (2) 13-90 (2) 13-143 (2) 13-195 (2) 13-248 (2)
13-39 (2) 13-91 (2) 13-144 (2) 13-196 (2) 13-249 (2)
13-40 (10) 13-92 (10) 13-145 (2) 13-197 (10) 13-250 (2)
13-41 (2) 13-93 (10) 13-146 (2) 13-198 (2) 13-251 (2)
13-42 (2) 13-94 (2) 13-147 (2) 13-199 (2) 13-252 (2)
13-43 (2) 13-95 (2) 13-148 (2) 13-200 (2) 13-253 (2)
13-44 (10) 13-96 (2) 13-149 (2) 13-201 (2) 13-254 (2)
13-45 (2) 13-97 (10) 13-150 (2) 13-202 (2) 13-255 (2)
13-46 (2) 13-98 (10) 13-151 (2) 13-203 (2) 13-256 (2)
13-47 (10) 13-99 (2) 13-152 (2) 13-204 (2) 13-257 (10)
13-48 (2) 13-100 (10) 13-153 (2) 13-205 (2) 13-258 (2)
13-49 (2) 13-101 (2) 13-154 (2) 13-206 (2) 13-260 (2)
13-50 (2) 13-102 (2) 13-155 (2) 13-207 (2) 13-261 (2)
13-51 (10) 13-103 (10) 13-156 (2) 13-208 (10) 13-262 (2)
13-52 (2) 13-104 (10) 13-157 (2) 13-209 (10) 13-263 (2)
13-53 (2) 13-105 (2) 13-158 (2) 13-210 (2) 13-264 (2)
13-54 (2) 13-106 (2) 13-159 (2) 13-211 (10) 13-265 (2)
13-55 (2) 13-107 (2) 13-160 (2) 13-212 (2) 13-266 (2)
13-56 (2) 13-108 (2) 13-161 (2) 13-213 (2) 13-267 (2)
13-57 (2) 13-109 (2) 13-162 (2) 13-214 (2) 13-268 (2)
102 SERIES 00-2-3

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13-269 (2) 13-322 (2) 13-375 (2) 13-428 (2) 15-18

13-270 (2) 13-323 (2) 13-376 (2) 15-19
13-271 (2) 13-324 (2) 13-377 (2) 14-1 (15) 15-20
13-272 (2) 13-325 (2) 13-378 (2) 14-2 (15) 15-21
13-273 (10) 13-326 (2) 13-379 (2) 14-3 (15) 15-22 (10)
13-274 (2) 13-327 (2) 13-380 (2) 14-4 (15) 15-23
13-275 (2) 13-328 (2) 13-381 (2) 14-6 (15) 15-24
13-276 (2) 13-329 (2) 13-382 (2) 14-7 (15) 15-25
13-277 (2) 13-330 (2) 13-383 (2) 14-8 (15) 15-26
13-278 (2) 13-331 (2) 13-384 (2) 14-9 (15) 15-27
13-279 (10) 13-332 (2) 13-385 (2) 14-10 (15) 15-28
13-280 (2) 13-333 (2) 13-386 (2) 14-11 (15) 15-29
13-281 (2) 13-334 (2) 13-387 (2) 14-12 (15) 15-30 (6)
13-282 (2) 13-335 (2) 13-388 (2) 14-13 (15) 15-31 (10)
13-283 (2) 13-336 (2) 13-389 (2) 14-14 (15) 15-32
13-284 (2) 13-337 (2) 13-390 (2) 14-16 (15) 15-33
13-285 (2) 13-338 (2) 13-391 (10) 14-17 (15) 15-34 (10)
13-286 (2) 13-339 (10) 13-392 (2) 14-18 (15) 15-35 (10)
13-287 (2) 13-340 (2) 13-393 (2) 14-19 (15) 15-36 (10)
13-288 (10) 13-341 (2) 13-394 (2) 14-20 (15) 15-37
13-289 (2) 13-342 (2) 13-395 (2) 14-21 (15) 15-38
13-290 (2) 13-343 (2) 13-396 (2) 14-22 (15) 15-39
13-291 (2) 13-344 (2) 13-397 (2) 14-24 (15) 15-40
13-292 (2) 13-345 (10) 13-398 (2) 14-25 (15) 15-41
13-293 (2) 13-346 (2) 13-399 (2) 14-26 (15) 15-42
13-294 (2) 13-347 (2) 13-400 (10) 14-27 (15) 15-43
13-295 (2) 13-348 (2) 13-401 (10) 14-28 (15) 15-44 (10)
13-296 (2) 13-349 (2) 13-402 (10) 14-30 (15) 15-45 (10)
13-297 (2) 13-350 (2) 13-403 (2) 14-31 (15) 15-46 (10)
13-298 (2) 13-351 (10) 13-404 (2) 14-32 (15) 15-47 (12)
13-299 (2) 13-352 (2) 13-405 (2) 14-33 (15)
13-300 (2) 13-353 (10) 13-406 (2) 14-34 (15)
13-301 (2) 13-354 (10) 13-407 (2) 14-35 (15)
13-302 (2) 13-355 (2) 13-408 (2) 14-36 (15)
13-303 (2) 13-356 (2) 13-409 (2) 14-37 (15)
13-304 (2) 13-357 (2) 13-410 (2)
13-305 (2) 13-358 (2) 13-411 (2) 15-1 (8)
13-306 (2) 13-359 (2) 13-412 (2) 15-2
13-307 (2) 13-360 (2) 13-413 (2) 15-3
13-308 (2) 13-361 (2) 13-414 (2) 15-4
13-309 (2) 13-362 (2) 13-415 (2) 15-5
13-310 (2) 13-363 (2) 13-416 (2) 15-6
13-311 (2) 13-364 (2) 13-417 (2) 15-7
13-312 (2) 13-365 (2) 13-418 (2) 15-8
13-313 (2) 13-366 (2) 13-419 (2) 15-9
13-314 (2) 13-367 (2) 13-420 (2) 15-10
13-315 (2) 13-368 (2) 13-421 (2) 15-11
13-316 (2) 13-369 (2) 13-422 (2) 15-12
13-317 (2) 13-370 (2) 13-423 (2) 15-13
13-318 (2) 13-371 (2) 13-424 (2) 15-14
13-319 (2) 13-372 (2) 13-425 (2) 15-15
13-320 (2) 13-373 (2) 13-426 (2) 15-16
13-321 (2) 13-374 (2) 13-427 (2) 15-17
00-2-4 102 SERIES

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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
¤
tank.
Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
FOREWORD CAPSCREW MARKINGS AND TORQUE VALUES
Capscrew Markings and torque values - Metric
Commercial Steel Class

8.8 10.9 12.9
Capscrew Head Markings
Body
Size Torque Torque Torque
Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb
6 0.92 9 5 0.71 7 4 1.2 12 9 0.71 7 4 1.4 14 9 0.71 7 4

7 1.4 14 9 1.1 11 7 1.8 18 14 1.1 11 7 2.3 23 18 1.1 11 7
8 2.5 25 18 1.8 18 14 3.4 33 25 1.8 18 14 4.1 40 29 1.8 18 14
10 4.6 45 33 3.1 30 25 6.1 60 45 3.1 30 25 7.1 70 50 3.1 30 25
12 8.2 80 60 5.6 55 40 10.7 105 75 5.6 55 40 12.7 125 95 5.6 55 40
14 12.7 125 90 9.2 90 65 16.8 165 122 9.2 90 65 19.9 195 145 9.2 90 65
16 18.4 180 130 14.3 140 100 24.5 240 175 14.3 140 100 29.6 290 210 14.2 140 100
18 23.5 230 170 18.4 180 135 32.6 320 240 18.4 180 135 40.8 400 290 18.4 180 135
00-24 102 SERIES

C
FOREWORD CAPSCREW MARKINGS AND TORQUE VALUES
Capscrew Markings and torque values - U.S. Customary
SAE grade number 5 8

Capscrew Head Markings
These are all SAE Grade 5 (3) line.
Capscrew Torque - Grade 5 Capscrew Capscrew Torque - Grade 8 Capscrew
Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum
kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb
1/4 - 20 0.92 9 7 0.82 8 6 1.5 15 11 0.82 8 6

- 28 1.2 12 9 0.92 9 7 1.8 18 13 0.92 9 7
5/16 - 18 2.0 20 15 1.6 16 12 3.1 30 22 1.6 16 12
- 24 2.3 23 17 1.9 19 14 3.4 33 24 1.9 19 14
3/8 - 16 4.1 40 30 2.5 25 20 5.6 55 40 2.5 25 20
- 24 4.1 40 30 3.6 35 25 6.1 60 45 3.6 35 25
7/16 - 14 6.1 60 45 4.6 45 35 9.2 90 65 4.6 45 35
- 20 6.6 65 50 5.6 55 40 9.7 95 70 5.6 55 40
1/2 - 13 9.7 95 70 7.6 75 55 13.3 130 95 7.6 75 55
- 20 10.2 100 75 8.2 80 60 15.3 150 110 8.2 80 60
9/16 - 12 13.8 135 100 11.2 110 80 19.4 190 140 11.2 110 80
- 18 15.3 150 110 11.7 115 85 21.4 210 155 11.7 115 85
5/8 - 11 18.4 180 135 15.3 150 110 26 255 190 15.3 150 110
- 18 21.4 210 155 16.3 160 120 29.6 290 215 16.3 160 120
3/4 - 10 33.1 325 240 26 255 190 46.9 460 340 26 255 190
- 16 37.2 365 270 29.1 285 210 52.5 515 380 29.1 285 210
7/8 - 9 50 490 360 38.7 380 280 76 745 550 38.7 380 280
- 14 54 530 390 42.8 420 310 84.1 825 610 42.8 420 310
1-8 73.4 720 530 58.1 570 420 112.2 1100 820 58.1 570 420
- 14 81.6 800 590 66.3 650 480 122.4 1200 890 66.5 650 480
102 SERIES 00-25

C
FOREWORD SYMBOLS
SYMBOLS
The following symbols have been used in this
manual to help communicate the intent of the in-
structions. When one of the symbols appears, it
conveys the meaning defined below:
WARNING - Serious personal injury or ex-

tensive property damage can result if the
warning instructions are not followed.
CAUTION - Minor personal injury can re-

sult or a part, an assembly, or the engine
can be damaged if the caution instructions
are not followed.
Indicates a REMOVAL or DISASSEMBLY

step.
Indicates an INSTALLATION or ASSEM-

BLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEA-

SUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE

will be given.
TIGHTEN to a specific torque.
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual

or another publication for additional in-
formation.
The component weights 23 kg (50 lb) or

more. To avoid personal injury, use a hoist
or get assistance to lift the component.
102 SERIES 00-27

@
FOREWORD ILLUSTRATIONS
ILLUSTRATIONS
The illustrations used in the "Repair Sections" of
this manual are intended to give an example of a
problem, and to show what to look for and where
the problem can be found. Some of the illustra-
tions are 'generic" and will not look exactly like
the engine or parts used in your application.
Some illustrations contain symbols to indicate
and action required, and an acceptable or not ac-
ceptable condition.
The illustrations are intended to show repair or

replacement procedures with the engine "in-chas-
sis". The illustration can differ from your applica-
tion, but the procedure given will be the same.
00-28 102 SERIES

C
GENERAL APPLICABLE MACHINE
102-2
Engine Serial No. Applicable machine
D31EX-21, D31PX-21 Bulldozer

SAA4D102E-2
PC160LC-7 Hydraulic excavator

PC200-7, PC200LC-7, PC228US-3, PC228USLC-3, PC270-7,
Hydraulic excavator
PC308USLC-3, PC220-7, PC220LC-7
Mobile crusher
BR120T-1, BR380JG-1 (Gara-Pagos)
WA150-5 Wheel loader
SAA6D102E-2 WA200-5 Wheel loader
WA250-5, WA250PT-5 Wheel loader
WA320-5 Wheel loader
GD555-3A, GD555-3C Motor grader
102 SERIES 01-1-2

(19)
GENERAL SPECIFICATIONS
102-2
Engine SAA4D102E-2
Applicable model D31EX-21 D37EX-21 D39EX-21

D31PX-21 D37PX-21 D39PX-21
No. of cylinders - Bore x Stroke mm 4 – 102 x 120

Total piston displacement ¬ {cc} 3.92 {3,920}
Firing order 1– 3–4–2
Overall length mm 920 920 920

Dimensions
Overall width mm 658 658 658

Overall height
(excluding exhaust pipe) mm 947 947 947
Overall height
(including exhaust pipe) mm — — —
58.2{78.0}/2,000 63.3{84.9}/2,000 70{94}/2,200

Flywheel horsepower kW{HP}/rpm (Net) (Net) (Net)
Performance
384{39.2}/1,300 412{42}/1,300 434{44.3}/1,300

Max. torque Nm{kgm}/rpm (Net) (Net) (Net)
High idling speed rpm 2,200 ± 50 2,200 ± 50 2,400 ± 50

+50 +50 +50
Low idling speed rpm 800 0 800 0 800 0
Min. fuel consumption ratio g/kW•h 224 224 218

{g/HP•h} {165} {165} {162}
Dry weight kg 400 400 400
Fuel injection pump BOSCH PES-A type

Governor BOSCH RSV centrifugal, all speed type
Lubricating oil amount 14 14 14

¬
(refil capacity) (12.5) (12.5) (12.5)
Coolant amount ¬ 7.0 (engine only) 7.0 (engine only) 7.0 (engine only)
Alternator 24V, 25A 24V, 25A 24V, 25A

Starting motor 24V, 5.5kW 24V, 5.5kW 24V, 4.5kW
Battery 12V92Ah x 2 12V92Ah x 2 12V88Ah x 2
Turbocharger HOLSET HX25 type HOLSET HX25 type HOLSET HX25 type
Air compressor — — —
Others With air cooled With air cooled With air cooled
aftercooler aftercooler aftercooler
01-7-7 102 SERIES

(19)
SAA4D102E-2
PC160LC-7 WA150-5
4 – 102 x 120
3.92 {3,920}
1– 3–4–2
1,013 786
722 715
— 1,924
1,293 —
82{110}/2,200 70.8{94.9}/2,000
(Net) (Net)
431{44}/1,500 402{41}/1,300
(Net) (Net)
2,490 ± 50 2,250 ± 50
1,050 ± 50 825 ± 50
212 219
{156} {161}
415 450
BOSCH PES-A type

BOSCH RSV centrifugal, all speed type
17.5 14
(16) (12.5)
7.0 (engine only) 7.0 (engine only)
24V, 35A 24V, 35A

24V, 4.5kW 24V, 5.5kW
12V95Ah x 2 12V95Ah x 2
HOLSET HX25 type HOLSET HX25 type

— —
With air cooled With air cooled
aftercooler aftercooler
102 SERIES 01-7-8

(19)
Engine SAA6D102E-2
PC200-7 PC228US-3 PC308USLC-3

Applicable model BR380JG-1
PC200LC-7 PC228USLC-3 PC270-7

Firing order 1–5–3–6–2–4
Overall length mm 1,320 1,320 1,320

Dimensions
Overall width mm 750 750 750

Overall height
(excluding exhaust pipe) mm 1,380 1,380 1,443
Overall height
(including exhaust pipe) mm — — —
107{143}/1,950 107{143}/1,950 134{180}/2,050

Flywheel horsepower kW{HP}/rpm (Net) (Net) (Net)
Performance
610{62.2}/1,500 610{62.2}/1,500 718{73.3}/1,500

Max. torque Nm{kgm}/rpm (Net) (Net) (Net)
+70
High idling speed rpm 2,200 ± 30 2,200 ± 30 2,330 _ 30
Low idling speed rpm 1,050 ± 25 1,050 ± 25 1,050 ± 25
Min. fuel consumption ratio g/kW•h 203 203 218
{g/HP•h} {151} {151} {160}
Dry weight kg 550 550 550

Lubricating oil amount 26.3 26.3 26.3

¬
(refil capacity) (24.0) (24.0) (24.0)
Coolant amount ¬ 9.0 (engine only) 9.0 (engine only) 9.0 (engine only)
Alternator 24V, 35A 24V, 35A 24V, 35A

Starting motor 24V, 4.5kW 24V, 4.5kW 24V, 4.5kW
Battery 12V120Ah x 2 12V120Ah x 2 12V120Ah x 2
Turbocharger HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type
Air compressor — — —
With air cooled With air cooled With air cooled
Others
aftercooler aftercooler aftercooler
01-7-9 102 SERIES

(18)
SAA6D102E-2
WA200-5 WA250-5 GD555-3A

BR120T-1 WA200PT-5 WA250PT-5 WA320-5 GD555-3C
6 – 102 x 120
5.88 {5,883}
1 – 5 – 3 – 6– 2 – 4
1,210 1,069 1,069 1,069 1,070
750 785 785 785 747
1,380 1,483 1,483 1,483 1,123
— — — — —
141{189}/2,050 95.2{127.7}/2,000 104.1{139.5}/2,000 127{170}/2,000 124.5{167}/2,000

(Gross) (Gross) (Gross) (Gross) (Gross)
740{75.7}/1,500 586{59.8}/1,400 627{64}/1,400 672{68.5}/1,500 743{75.7}/1,500

(Gross) (Gross) (Gross) (Gross) (Gross)
2,330 ± 50 2,250 ± 50 2,250 ± 50 2,250 ± 50 2,230 ± 50
1,050 ± 25 825 ± 50 825 ± 50 900 ± 25 900 ± 50
203 224 224 224 227

{151} {167} {167} {167}
550 580 580 600 550
BOSCH PES-A type

BOSCH RSV centrifugal, all speed type
26.3 21.8 21.8 21.8 26.3

(24.0) (19.5) (19.5) (19.5) (24.0)
9.0 (engine only) 9.0 (engine only) 9.0 (engine only) 9.0 (engine only) 9.0 (engine only)
24V, 35A 24V, 35A 24V, 35A 24V, 60A 24V, 35A
24V, 4.5kW 24V, 4.5kW 24V, 4.5kW 24V, 5.5kW 24V, 5.5kW
12V120Ah x 2 12V120Ah x 2 12V120Ah x 2 12V120Ah x 2 12V140Ah x 2
HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type
— — — — —
With air cooled With air cooled With air cooled With air cooled With air cooled
aftercooler aftercooler aftercooler aftercooler aftercooler
102 SERIES 01-7-10

(19)
Engine SAA6D102E-2
Applicable model PC308USLC-3 PC220-7

PC220LC-7

Firing order 1–5–3–6–2–4
Overall length mm 1,320 1,320

Dimensions
Overall width mm 750 750

Overall height
(excluding exhaust pipe) mm — 1,383
Overall height
(including exhaust pipe) mm 1,443 —
134{180}/2,050 125{168}/2,000
Flywheel horsepower kW{HP}/rpm (Net) (Net)
Performance
718{73.3}/1,500 684{69.8}/1,500
Max. torque Nm{kgm}/rpm (Net) (Net)
+70 +80
High idling speed rpm 2,330 _ 30 2,260 _ 20
Low idling speed rpm 1,050 ± 25 1,050 ± 25
Min. fuel consumption ratio g/kW•h 218 218
{g/HP•h} {163} {163}
Dry weight kg 550 550

Lubricating oil amount 26.3 26.3

¬
(refil capacity) (24.0) (24.0)
Coolant amount ¬ 9.0 (engine only) 9.0 (engine only)
Alternator 24V, 35A 24V, 35A

Starting motor 24V, 4.5kW 24V, 4.5kW
Battery 12V120Ah x 2 12V120Ah x 2
Turbocharger HOLSET HX35 type HOLSET HX35 type

Air compressor — —
With air cooled With air cooled
Others
aftercooler aftercooler
01-7-11 102 SERIES

(19)
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING

4D102E-1 (PC60-7)
LEFT-HAND VIEW
fl Depending on the applicable model, the view may be different from the drawing.
01-8 102 SERIES

B
GENERAL GENERAL ASSEMBLY DRAWING
The following diagrams show the positions of the main external engine components, filters, and preven-
tive maintenance points. Depending on the engine model, the position of the external components may
be different.
Enaine air inlet

Intake air preheater
Hiah Pressure
Fuel filter
fuel lines
Fuel injection Coolant heater (OPT)

PUli?P
3/4 NPTF finch)
Air comoressor
air inlet Fuel inlet connection
l/4 NPTF (inch)
Air comPressor
Speed sensor
nick-up
Ens ine data

nla te Fuel feed numn
Oil Pressure
pick-up
l/B NPTF finch) Dipstick
Intake side view
Enaine rear
lifting bracket
Turbocharaer exhaust
out let
\
Fuel return
circuit \ \
Flywheel -
Flexible Plate
mounting holes
Rear view
Flywheel housing
SXEOI 397
01-20 102 SERIES
@I
GENERAL ASSEMBLY DRAWING
GENERAL
Turbocharoer air
Fuel injection inlet
nozzles
Oil filler
Engine front
liftins bracket
Water outlet
:ypfk;at ins oi I
Start ins motor
Coolant inlet
Oil nan heater

mount ins Heater water return
l/2 NPTF finch)
Oit drain alus 1 Turbocharser side view
Turbocharner air Turbocharoer air

inlet out let
\
Enaine air inlet
Alternator Fuel injection numn

drive sear
Air compressor
air outlet
Water somn y
Coolant inlet N Front sear case
\
Fan drive belt
/
Vibration damper SXE01398
102 SERIES
01-21
@
GENERAL ENGINE PERFORMANCE CURVE
102E-2
Engine Serial No. Applicable machine Page
D31EX, PX-21 01-34-18
D37EX, PX-21 01-34-19

SAA4D102E-2
D39EX, PX-21 01-34-20
PC160LC-7 01-34-21
PC200-7, PC200LC-7, PC228US, USLC-3 01-34-31
BR120T-1 01-34-32
PC270-7, PC308USLC-3, BR380JG-1 01-34-33
WA150-5 01-34-22
SAA6D102E-2 WA200-5, WA200PT-5 01-34-37
WA250-5, WA250PT-5 01-34-34
WA320-5 01-34-35
GD555-3A, GD555-3C 01-34-36
PC220-7, PC220LC-7 01-34-38
102 SERIES 01-21-2

(19)
SAA4D102E-2 (D31EX-21, D31PX-21)

Flywheel horsepower : 58.2 kW {78 HP} /2,000 rpm (Net)
Maximum torque : 384 Nm {39.2 kgm} /1,300 rpm (Net)
01-34-18 102 SERIES

(19)
SAA4D102E-2 (D37EX-21, D37PX-21)

Flywheel horsepower : 63.3 kW {84.9 HP} /2,000 rpm (Net)
Maximum torque : 412 Nm {42 kgm} /1,300 rpm (Net)
102 SERIES 01-34-19

(19)
SAA4D102E-2 (PC160LC-7)
Flywheel horsepower : 82.4 kW {110.5 HP} /2,200 rpm (Net)
Maximum torque : 431 Nm {44 kgm} /1,500 rpm (Net)
102 SERIES 01-34-21

C
SAA4D102E-2 (WA150-5)
Flywheel horsepower : 74.2 kW {99.5 HP} /2,000 rpm (Gross)
Maximum torque : 408 Nm {41.6 kgm} /1,300 rpm (Gross)
01-34-22 102 SERIES

(19)
SAA6D102E-2 (PC200-7, PC200LC-7, PC228US-3, PC228USLC-3)

Flywheel horsepower : 107 kW {143 HP} /1,950 rpm (Net)
102 SERIES 01-34-31

C
SAA6D102E-2 (BR120T-1)
Flywheel horsepower : 141 kW {189 HP} /2,050 rpm (Gross)
01-34-32 102 SERIES

C
SAA6D102E-2 (PC270-7, PC308USLC-3, BR380JG-1)

102 SERIES 01-34-33

(18)
SAA6D102E-2 (WA250-5, WA250PT-5)

Maximum torque : 627 Nm {64 kgm} /1,400 rpm (Gross)
01-34-34 102 SERIES

(19)
SAA6D102E-2 (WA200-5, WA200PT-5)

102 SERIES 01-34-37

(19)
SAA6D102E-2 (PC220-7, PC220LC-7)

01-34-38 102 SERIES

(19)
II STRUCTURE AND FUNCTION
General structure.. ....................................... 1 I- 2

Intake and exhaust devices.. ....................... 1 I- 4
Air cleaner ............................ . ....................... .I I- 6
Turbocharger ............................................... 1 I- 7
Cylinder head ............................................... II-10
Cylinder block .............................................. 11-14
Main moving parts ...................................... 11-18
Timing gear portion.. ................................... 1 l-23
Front gear cover .......................................... 1 l-24
Camshaft timing pin .................................... 1 l-25
Valve mechanism ........................................ 1 l-26
Oil pan ........................................................... 1 l-29
Flywheel, flywheel housing ........................ 1 I-30
Lubrication system diagram ....................... 1 l-33
Oil pump ....................................................... 11-38
Oil filter, oil cooler ....................................... 1 I-40
Regulator valve, safety valve.. .................... 1 l-42
Fuel system diagram ................................... 1 l-43
Fuel injection pump.. ................................... 1 l-48
Timing lock pin for fuel injection pump.. ... 1 I-50
Fuel filter ...................................................... .ll-51
Fuel injection nozzle .................................... 1 l-52
Fuel cut solenoid .......................................... 11-53
Cooling system diagram ............................. 11-55
Water pump ................................................. .ll-57
Thermostat.. .................................................. II- 58
Fan drive ...................................................... .I l-59
Air compressor ............................................ 1 I-60
Flow diagrams-compressed air system.. ... 1 l-62
Alternator ..................................................... .I l-64
Starting motor ............................................. 1 l-65
Starting aid .................................................... 11-67
1 l-l
STRUCTURE AND FUNCTION INTAKE AND EXHAUST DEVICES
ixhaust device)
j ,.;:
....-...l. [ .,..,
:I :. j
:
SDE00272
1. Muffler
2. Exhaust pipe
3. Exhaust pipe (turbocharger - muffler)
4. Turbocharger
5. Exhaust manifold
1 l-5
STRUCTURE AND FUNCTION TURBOCHARGER
Lubrication of turbocharger (engine with turbocharger)
1. Oil supply pipe

2. Oil drain pipe
The oil to the turbocharger is filtered, cooled, and

pressurized, then passes from the filter head and
goes through the oil supply pipe (1) to the turbo-
charger. The oil then passes through the oil drain
pipe (2) connected to the bottom of the turbo-
charger housing, goes through the block fitting and
returns to the oil pan.
102 SERIES 11-9

C
STRUCTURE AND FUNCTION CYLINDER BLOCK
CYLINDER BLOCK
(S)4D102E-1
SAA4D102E-2
fl Depending on the machine model, the actual
component may be different from the diagram.
1. Main bearing cap a. Piston cooling nozzle

2. Main bearing cap bolt b. Thrust face (top face only, No. 4 journal)
3. Cylinder block
4. Cam bushing (journal No. 1)
5. Dowel ring (main bearing cap positioner)
11-14 102 SERIES

(17)
STRUCTURE AND FUNCTION CYLINDER BLOCK
(S)6D102E-1, SA6D102E-1
SAA6D102E-2
fl Depending on the machine model, the actual com-
ponent may be different from the diagram.
1. Main bearing cap a. Piston cooling nozzle

2. Main bearing cap bolt b. Thrust face (top face only, No. 6 journal)
3. Cylinder block
4. Cam bushing (journal No. 1)
5. Dowel ring (main bearing cap positioner)
6. Cam follower cover
7. Breather hose
11-15-1 102 SERIES

(17)
STRUCTURE AND FUNCTION MAIN MOVING PARTS
MAIN MOVING PARTS

(S)4D102E-1
SAA4D102E-2
1. Crankshaft 11. Second ring a: Ring carrier

2. Crankshaft gear 12. Oil ring b: Toroidal
(No. of teeth: 36) 13. Connecting rod cap c: Re-entrant
3. Main bearing 14. Main cap d: Piston cooling nozzle
4. Connecting rod bearing 15. Main cap bolt
5. Connecting rod 16. Connecting rod cap bolt
6. Cylinder block (no lining) 17. Thrust bearing
7. Piston (top face only No. 4 journal)
8. Connecting rod bushing 18. Pin
9. Piston pin 19. Crankshaft pulley
10. Top ring
11-18 102 SERIES

(17)
STRUCTURE AND FUNCTION MAIN MOVING PARTS
(S)6D102E-1, SA6D102E-1
SAA6D102E-2
1. Crankshaft 11. Second ring a: Ring carrier

2. Crankshaft gear 12. Oil ring b: Toroidal
(No. of teeth: 36) 13. Connecting rod cap c: Re-entrant
3. Main bearing 14. Main cap d: Piston cooling nozzle
4. Connecting rod bearing 15. Main cap bolt
5. Connecting rod 16. Connecting rod cap bolt
6. Cylinder block (no lining) 17. Thrust bearing
7. Piston (top face only No. 6 journal)
8. Connecting rod bushing 18. Pin
9. Piston pin 19. Crankshaft pulley
10. Top ring
11-19-1 102 SERIES

(17)
STRUCTURE AND FUNCTION VALVE MECHANISM
Valve timing
Valve lift Valve angle (Open, closed)

S4D102E-1 S4D102E-1
4D102E-1 S6D102E-1 4D102E-1 S6D102E-1
SA6D102E-1 SA6D102E-1
6D102E-1 6D102E-1
SAA4D102E-2 SAA4D102E-2
Intake 10.6 mm 9.9 mm a 10˚ 11.5˚
Intake
Exhaust 11.7 mm 11.7 mm b 30˚ 9.5˚
c 53˚ 53˚
Exhaust
d 19˚ 19˚
12. Spring seat

13. Valve cotter
14. Valve spring
15. Valve stem seal (intake, exhaust)
16. Rocker arm
102 SERIES 11-27

(17)
STRUCTURE AND FUNCTION FLYWHEEL, FLYWHEEL HOUSING
I--* -
LA SDE00293
Rear seal
. For dry type: Single lip with dust seal
. For wet type: Double lip
11-31
STRUCTURE AND FUNCTION LUBRICATION SYSTEM DIAGRAM
Flow of lubricating oil
Oil pump 1. Gerotor, lubricating pump

This engine uses gerotor type oil pump (1). The 2. Pressure regulator valve
cavities machined in the block are common to all 3. Full flow filter
engines. On the 6-cylinder engine, a wide gerotor 4. Oil cooler
is used to increase the volume of the pump, so 5. Filter bypass valve
there is no interchangeability with the oil pump
used on the 4-cylinder engine.
Regulator valve
Oil pressure regulator valve (2) is designed to keep
the engine oil pressure below 449 kPa {4.6 kg/cm2
}. If the oil pressure from the pump exceeds 449
kPa {4.6 kg/cm2 }, the valve opens and the cover of
the dump port comes off, so part of the oil flows
to the oil pan. The minimum permissible limit for
the oil pressure is the same for the 4-cycle engine
and 6-cycle engine. There is a tolerance for the
component and oil passage, so there is a possibil-
ity of a difference of a maximum oil pressure of 69
kPa {0.7 kg/cm2} appearing between engines.
11-34 102 SERIES

C
Oil cooler
On this engine, a full-flow plate shape oil cooler
(3) is used. The oil flows through the passage cast
in the cooler cover and goes to the element, where
it is cooled in the element by the engine cooling
water flowing through the plate. On the 4-cycle
engine, element (A) with five plates is used, and
on the 6-cycle engine, element (B) with seven plates
is used.
There is a difference in the resistance and pump
volume of the plates, so there is no interchange-
ability in the oil cooler components between the
two engines. If the correct component is not used,
it will cause high temperature, low temperature,
or the formation of varnish or sludge.
Caution: Up to 10/21/86, a 9-plate oil cooler element
was used for the 6-cylinder engine.
Oil filter
After the oil is cooled, it is sent to full-flow oil filter
(4). The filter on the 6-cylinder engine is slightly
longer than the filter on the 4-cylinder engine.
Caution: Even if the 6-cylinder engine filter is
used on the 4-cylinder engine, there
will be no increase in the replace-
ment interval. Do not use a 4-cylin-
der engine filter on the 6-cylinder
engine under any circumstances.
This will cause a drop in the filtering
capacity and will cause an increase
in clogging.
Oil cooler bypass valve

Bypass valve (5) is installed in the oil cooler cover
to allow the oil to flow through the bypass when
the filter is clogged. The valve is designed so that
when the filter is clogged and the drop in pressure
on both sides of the filter exceeds 1.4
kg/cm2 (138 kPa) (20 psi), the valve opens and al-
lows the oil to flow to the engine. When the filter
is clogged, the oil pressure drops within 0.6 kg/cm2
(60 kPa) (10 psi) lower than the normal operating
oil pressure. This can be observed on the oil pres-
sure gauge.
To avoid this condition, it is best to replace the fil-
ter at the drain interval given in the Operation and
Maintenance Manual, Bulletin No. 3810205-10.
102 SERIES 11-35

C
Lubrication of output power related equipment
11-36 102 SERIES

C
The main bearing and valve train are lubricated by

oil sent directly under pressure from the main oil
rifle. Other output power related parts, connect-
ing rod, piston, and camshaft receive the pressur-
ized oil indirectly from the main oil rifle.
The oil passes through the crankshaft oil pressure

and is supplied to the connecting rod bearing. The
oil passes through the oil hole in the main bearing
saddle, and is supplied to the camshaft journal. Oil
is sent from the small oil hole in the main bearing
saddle to the piston cooling nozzle. The oil sprayed
from the nozzle acts to lubricate the piston pin.
There is no piston cooling nozzle in main bearing

saddle No. 1. The No. 1 cylinder receives the lubri-
cating and cooling spray from the nozzle of the No.
2 bearing saddle. The No. 2 cylinder receives the
spray from the No. 3 bearing saddle, and so on.
Lubrication for the valve train is carried out by oil

sent through a separate hole in the block. The oil
passes through the oil hole and is sent to the oil
transfer slot in the cylinder head gasket. It passes
around the outside diameter of the head bolts and
flows to the groove in the bottom of the rocker le-
ver support, and goes up through the vertical hole
in the support. The oil from this hole passes
through the oil hole in the rocker lever shaft and
reaches the rocker lever. The oil passes through
the oil hole in the rocker lever, fills the groove cast
in the top of the lever, and lubricates the valve stem,
push rod, and tappet.
11-37
STRUCTURE AND FUNCTION FUEL SYSTEM DIAGRAM
(S)4D102E-1, SAA4D102E-2
1. Fuel tank 5. Fuel filter

2. Gauze filter 6. Overflow valve
3. Priming pump 7. Fuel injection pump
4. Feed pump 8. Fuel injection nozzle
11-44 102 SERIES

C
OUTLINE OF FUEL SYSTEM
Components of fuel system and flow of fuel Components of fuel system and flow of fuel
(Bosch VE, Lucas RSV) (Bosch A, Zexel A)
Almost all the engines are equipped with a fuel feed The cam driven piston style fuel feed pump
pump driven by a cam. Of the rotor type fuel injec- supplies normal fuel pressure to the fuel injec-
tion pumps, the following two types can be used tion pump. The flow of fuel starts from the fuel
as the fuel feed pump. supply pump, but the pump sucks in fuel from
I) Diaphragm style fuel feed pump the fuel tank. In this case, a prefilter or screen
2) Piston type fuel feed pump must be installed to remove the larger particles
The piston style pump is an option, and it is pos- of dirt from the fuel before it reaches the fuel
sible to disassemble, clean, and assemble the fuel feed pump. The fuel feed pump supplies low-
feed pump if the reassembly kit is used. The flow pressure fuel to the fuel injection pump at 172
of fuel starts from the fuel feed pump, but the pump kPa {I .7 kg/cm21 through the fuel filter head and
sucks in the fuel from the fuel tankthrough a forced filter.
prefilter. The pump sends the fuel to the fuel filter
head at a low pressure of 21 - 35 kPa. The fuel The fuel injection pump creates the high injec-
passes through the filter and is supplied to the dis- tion pressure needed for combustion, and force
tributor spray pump. feeds the fuel to the injectors through the high
pressure fuel line.
The distributor spray pump forms the high spray
pressure needed for combustion, and sends the The B series engines use a closed nozzle, hole-
fuel to each injector through the separate high-pres- type injector. When the high-pressure fuel
sure fuel line. reaches the injector, the needle valve is pushed
up by the pressure against the tension of the
When the high-pressure fuel reaches the injector, spring, and fuel is sent to the combustion
the needle valve is pushed up by the pressure chamber.
against the tension of the spring, and fuel is sent
to the combustion chamber. On engines equipped with the P7100 fuel in-
jection pump, the manifold sends the fuel leak-
The fuel leaking from the needle valve enters the ing from the injector to the fuel filter inlet port.
fuel drain manifold. The fuel drain manifold is con- On the engines equipped with the Nihon Denso
trolled by the air from the distributor injection EP-9 fuel injection pump, the manifold sends
pump, and the oil leaking from the injector is re- the fuel leaking from the injector to the fuel
turned to the fuel tank. tank.
11-46
Components of fuel system and flow of fuel

The diagram below shows the components of the fuel system.
1. Fuel from fuel tank 8. Robot Bosch P7100 injection pump

2. Pre-filter or screen 8A. Robot Bosch rotary injection pump
3. Lift pump 9. Fuel drain manifold
4. Fuel/water separator 10. High pressure line
5. Fuel filter 11. Robot Bosch 17 mm nozzle, hole-type in-
6. Low pressure fuel supply line jector
7. Turbo boost control line 12. Fuel returns to fuel tank
102 SERIES 11-47

C
STRUCTURE AND FUNCTION TIMING LOCK PIN FOR FUEL INJECTION PUMP
TIMING LOCK PIN FOR FUEL INJECTION PUMP

Ir Depending on the machine model, the ac-
tual component may be different from the
diagram.
I-l:Condition of timing lock for timing lock pin
(When checking the injection timing of the No.
1 cylinder, the pin is installed in the reverse of
the condition when operating.)
I-2:Condition when timing lock pin is out of posi-

tion
(When operating)
I SEE00304
SEE00305
Damper-proof bolt _
SEE00306
11-50
STRUCTURE AND FUNCTION FUEL FILTER
FUEL FILTER
* Depending on the machine model, the actual component may be different from the diagram.
SDE00307
1. Bracket (filter head) Fuel filter

2. Connector . Filtering area: 0.15 m2
3. Seal
4. Cartridge
A. Fuel inlet port

B. Fuel outlet port
11-51
STRUCTURE AND FUNCTION FUEL INJECTION NOZZLE
FUEL INJECTION NOZZLE

* Depending on the machine model, the actual component may be different from the diagram.
“0”
37 0
2
--$3
,/--e t
SEE00308
1. Gasket Fuel injection nozzle

2. Retaining cap . Type: Bosch multiple-hole type
3. Nozzle body Cylindrical type
4. Needle valve . Injection pressure (cracking pressure):
5. Disc 21.56 MPa (220 kg/cm21
6. Seal ring . Cracking pressure adjustment:
7. Connector seal Shim adjustment
8. Shim (for adjusting cracking pressure)
9. Spring A. Fuel inlet port (from injection pump)
IO. Push rod B. Fuel outlet port
(inside combustion chamber)
C. Fuel return port (to fuel tank)
11-52
STRUCTURE AND FUNCTION FUEL CUT SOLENOID
FUEL CUT SOLENOID

B Contact method (normally energized)
* Depending on the machine model, the actual component may be different from the diaoram.
SEE00312
1. Case Solenoid
2. Return spring Type: Synchrostart drip-proof
3. Stop lever type
4. Fuel control lever Rated voltage: DC24V
5. Solenoid Actuating current: Starting to pull: Approx. 25A
Completing pulling: 0.5 A
Cl. Pull-in coil Stroke: 25.4 mm
C2. Hold coil Weight: 1 kg
l When the engine is started, electricity flows

through the solenoid, so the solenoid plunger
is actuated and expands return spring (2) (built
s
into the solenoid), pulls it to the engine run po- 4
0
sition and holds it there.
. When stopping the engine, if the starting key
0
is returned to the STOP position, the flow of A
electricity in the solenoid stops. The magnetic Run 3
00
force of the solenoid is cut, so the stop lever of sto
the injection pump is moved to the STOP po-
sition (NO INJECTION) by the force of the re-
turn spring. The solenoid plunger is also pulled
back at the same time, and the engine stops.
. When the engine is running, the fuel injection
amount is controlled by fuel control lever (4). SEE00313
l When installing the fuel solenoid valve, adjust
clearance A (see TESTING AND ADJUSTING).
11-53
STRUCTURE AND FUNCTION FAN DRIVE
102E-2
fl All the pulleys are for polyvinyl V-belts.
Outside diameter of pulley (mm)

Engine Machine model a b c d e
(Alternator) (Fan) (Tension) (Crankshaft) (Water pump)
D31EX-21
D31PX-21
D37EX-21
D37PX-21 80 209 73.9 173 88
D39EX-21
D39PX-21
SAA4D102E-2
PC160LC-7 77.5 195 73.9 173 88
(ª1)
WA150-5 77.5 157 73.9 173 88
PC200-7
77.5 182 73.9 173 88
PC200LC-7
PC228US-3
77.5 204 73.9 173 88
PC228USLC-3
(ª1)
BR120T-1 77.5 177 73.9 173 88
SAA6D102E-2 BR380JG-1 77.5 172 73.9 173 88
WA200-5
WA200PT-5 (ª1)
WA250-5 77.5 157 73.9 173 88
WA250PT-5
WA320-5
GD555-3A (ª1)
80 157 73.9 173 88
GD555-3C
PC220-7
PC220LC-7 77.5 172 73.9 173 88
PC270-7
PC308USLC-3
ª1. Engine without fan.
102 SERIES 11-59-2

(19)
STRUCTURE AND FUNCTION AIR COMPRESSOR
AIR COMPRESSOR
Outline of air compressor system Caution: The cylinder head and unload compo-
Normally, the compressed air system consists of nents on the Holset SS161B air compres-
a gear driven air compressor, air governor, air sor are used for various engines, so
tank, and piping. maintenance can be carried out without
removing the air compressor. In this
manual, the explanation of the methods
for maintenance of the air compressor
unloader components are given for the
condition when the compressor is still
installed to the engine. When carrying
out maintenance on components or
other parts inside the air compressor, the
compressor must be removed from the
engine. For details of the procedure for
disassembly and assembly of the air
compressor, see SS192B shop manual,
Bulletin No. 3810433.
The Holset SS191 air compressor (1) is an engine The Holset SS296 air compressor is an engine
driven piston type compressor which supplies driven piston type compressor which supplies
compressed air to drive the air operated compo- compressed air to drive the air operated compo-
nents. The compressor operates continuously, nents. The compressor operates continuously,
but it has two operating modes (“load” and “un- but it has two operating modes (“load” and “un-
load”). The operating mode is controlled by a load”). The operating mode is controlled by a
pressure operated governor and compressor un- pressure operated governor and compressor un-
loading assembly. When the air line reaches the loading assembly.
set pressure, the governor (2) sends an air signal
to the air compressor unloader assembly and sets The SS296 air compressor used on the B series
the unloader valve with the compressor suc- engine uses an (E type) unloader. The economy
tion valve open, so this stops the flow of com- (E type) unloader system is designed to reduce
pressed air into the air line. It uses the air in the the pumping loss and engine boost pressure loss
air line, so the pressure goes down. When the air by the compressor intake valve when operating
pressure reaches the set pressure, the governor in the unloader mode.
exhausts the air signal sent to the compressor
unloader assembly, so the compressor again When the air line reaches the set pressure, the
starts to send compressed air to the air line. governor sends an air signal to the air compres-
sor unloader assembly and sets the unloader
There are two types of cooling for the air com- valve with the compressor suction valve open, so
pressor: air cooled and water cooled. The only this stops the flow of compressed air into the air
difference between these two types of cooling is line.
that modification has been made to the cylinder
head to include a water passage. Caution: The pressure inside the system must be
maintained by keeping the discharge
There are two types of installation for the air com- valve closed at the outlet port end of the
pressor: one type is installed to the power steer- discharge valve.
ing pump housing, and the other is not installed
to it. It uses the air in the air line, so the pressure goes
down. When the air pressure reaches the set pres-
On the 102 series engine, it is possible to use sure, the governor exhausts the air signal sent to
other brands of compressor. The troubleshoot- the compressor unloader assembly, so the com-
ing procedures for these air compressors is very pressor again starts to send compressed air to
similar to the Holset SS191B. For details of the the air line.
torque value and repair methods, see the manual
issued by the air compressor manufacturer.
11-60 102 SERIES

C
STRUCTURE AND FUNCTION AIR COMPRESSOR
A Caution:Machines
type)
which use a Holset (E
air compressor and are
equipped with a dehumidifier to
carry out ventilation during opera-
tion ofthe unload compressor must
have an air compressor valve in-
stalled to prevent excessive oil con-
sumption.
If it is impossible to maintain the air line pres-

sure with the exhaust valve during unload opera-
tions, air is sent out from the compressor cylin-
der to lower the pressure (back pressure) inside
the cylinder. If the seal of the intake valve in the
unloader cap is loosened and the exhaust valve
becomes a one way pressure starting valve, air
will stop flowing to the cylinder. When the com-
pressor cylinder pressure becomes lower than the
crankcase pressure, oil is sucked in from the pis-
ton ring and sent to the oil line.
11-61
STRUCTURE AND FUNCTION FLOW DIAGRAMS-COMPRESSED AIR SYSTEM
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM

With air dryer
Without air dryer
1. Compressor
2. Governor
3. Air dryer
4. Check valve
(normally built into dryer)
5. Reservoir (wet tank)
11-62 102 SERIES

C
STRUCTURE AND FUNCTION FLOW DIAGRAMS-COMPRESSED AIR SYSTEM
E type Holset SS296BE with humidifier
1. Compressor
2. Governor
3. Air conditioner valve
4. Air dryer
5. Check valve (normally built into dryer)
6. Reservoir (wet tank)
7. Check valve
102 SERIES 11-63

C
STRUCTURE AND FUNCTION ALTERNATOR
Alternator with built-in regulator (25A)

1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Field coil
3. Terminal R 6B. Primary energized resistance
4. Terminal B 6C. Regulator
5. Terminal E
Pulley
Engine Machine model Type Specification Weight
Outside (kg)
No. of steps diameter (mm)
D31EX-21
D31PX-21
D37EX-21
SAA4D102E-2 D37PX-21 Nikko Denki, Polyethylene V-
open type 24V, 25A 80 6.5
D39EX-21 belt, 8 grooves
D39PX-21
PC128US-2
PC138US-2
102 SERIES 11-64-1

(19)

1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Field coil
3. Terminal R 6B. Primary energized resistance
4. Terminal B 6C. Regulator
5. Terminal E
Pulley
Outside (kg)
WA100-3 Nikko Denki, Polyethylene V-
S4D102E-1 24V, 35A 80 8.0
GD305A-3, GD355A-3 open type belt, 8 grooves
GD405A-3 Nikko Denki, Polyethylene V-
S6D102E-1 open type 24V, 35A belt, 8 grooves 80 8.0
GD505A-3A
Nikko Denki, Polyethylene V-
SA6D102E-1 WA300-3 open type 24V, 35A belt, 8 grooves 80 8.0
D31EX-21, D31PX-21 Nikko Denki, Polyethylene V-

SAA4D102E-2 D37EX-21, D37PX-21 open type 24V, 35A belt, 8 grooves 80 8.0
D39EX-21, D39PX-21
11-64-2 102 SERIES

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1. Alternator 5. Terminal IG 6C. Load of L terminal

2. Alternator pulley 6. Internal connection diagram 6D. Key switch
3. Terminal B 6A. Alternator assembly 6E. Battery
4. Terminal L 6B. Regulator
Pulley
Outside (kg)
PC200-6 Nihon denso, 24V, 35A Polyethylene V-
S6D102E-1 open type belt, 8 grooves 77.5 4.7
PC200-6 EXCEL
Nihon denso, Polyethylene V-
SA6D102E-1 PC220-6 open type 24V, 35A belt, 8 grooves 77.5 4.7
SAA4D102E-2 WA150-5 open type 24V, 35A belt, 8 grooves 77.5 4.7
PC200-7 (26282900 – 26328689)
PC200LC-7 (26282900 – 26328689)
PC220-7 (26287717 – 26335033)
PC220LC-7 (26287717 – 26335033)
PC228US-3 (26274903 – 26307087)
PC228USLC-3
SAA6D102E-2 (26274903 – 26307087) Nihon denso, 24V, 35A Polyethylene V- 77.5 4.7
PC270-7 open type belt, 8 grooves
GD555-3A, 3C
BR120T-1
BR380JG-1
WA200-5, WA200PT-5
WA250-5, WA250PT-5
102 SERIES 11-64-3

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1. Alternator 4B. Regulator

2. Alternator pulley 4C. Load of L terminal
3. Terminal B 4D. Key switch
4. Internal connection diagram 4E. Battery
4A. Alternator assembly
Pulley
Outside (kg)
SAA4D102E-2 PC160LC-7 Nihon denso, Polyethylene V-

WA150-5 open type 24V, 35A belt, 8 grooves 77.5 4.7
PC200-7 (26328690 and up)
PC200LC-7
(26328690 and up)
PC228US-3
(26307088 and up)
PC228USLC-3 Nihon denso, Polyethylene V-
SAA6D102E-2 (26307088 and up) open type 24V, 35A 77.5 4.7
belt, 8 grooves
PC220-7 (26335034 and up)
PC220LC-7
(26335034 and up)
WA200-5, WA200PT-5
WA250-5, WA250PT-5
11-64-4 102 SERIES

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1. Alternator 5. Terminal IG 6C. Load of L terminal

2. Alternator pulley 6. Internal connection diagram 6D. Key switch
3. Terminal B 6A. Alternator assembly 6E. Battery
4. Terminal L 6B. Regulator
Pulley
Outside (kg)
S4D102E-1 PW128UU-1 open type 24V, 60A belt, 8 grooves 77.5 6.3
PC228UU-1 Nihon denso, Polyethylene V-
S6D102E-1 (tunnel specification) open type 24V, 60A belt, 8 grooves 77.5 6.3
SAA4D102E-2 WA150-5 open type 24V, 60A belt, 8 grooves 77.5 6.3
PC200-7 (26282900 – 26328689)
PC200LC-7 (26282900 – 26328689)
PC228US-3 (26274903 – 26307087)
PC228USLC-3
(26274903 – 26307087)
(tunnel specification) Nihon denso, Polyethylene V-
SAA6D102E-2 PC220-7 (26287717 – 26335033) open type 24V, 60A belt, 8 grooves 77.5 6.3
PC220LC-7 (26287717 – 26335033)
PC270-7
PC308USLC-3
WA200-5, WA200PT-5
WA250-5, WA250PT-5
102 SERIES 11-64-5

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1. Alternator 4B. Regulator

2. Alternator pulley 4C. Load of L terminal
3. Terminal B 4D. Key switch
4. Internal connection diagram 4E. Battery
4A. Alternator assembly
Pulley
Outside (kg)
SAA4D102E-2 WA150-5
PC200-7 (26328690 and up)
PC200LC-7
(26328690 and up)
PC220-7 (26335034 and up)
PC220LC-7
(26335034 and up) Nihon denso, Polyethylene V- 6.3
SAA6D102E-2 PC228US-3 open type 24V, 60A belt, 8 grooves 77.5
(26307088 and up)
PC228USLC-3
(26307088 and up)
(tunnel specification)
WA200-5, WA200PT-5
WA250-5, WA250PT-5
WA320-5
11-64-6 102 SERIES

(19)
STRUCTURE AND FUNCTION STARTING MOTOR
With separate safety relay (4.5 kW)

1. Pinion gear 5. Jump start protective cover 8B. Starting switch

2. Magnetic switch 6. 50 (Terminal C) 8C. Battery
3. Starting motor assembly 7. 30 (Terminal B) 8D. 30 (Terminal B)
4. Warning plate 8. Internal connection diagram 8E. 50 (Terminal C)
(For jump start prohibition) 8A. Relay
Engine Machine model Type Specification No. of pinion teeth Weight (kg)
PC120 Nihon denso, 24V, 4.5kW 8.4
S4D102E-1 tunnel specification sealed type 10
S6D102E-1 PC200-6
Nihon denso, 24V, 4.5kW 10 8.4
SA6D102E-1 GD405A-3 sealed type
GD505A-3A
D39EX-21
Nihon denso, 24V, 4.5kW 8.4
SAA4D102E-2 D39PX-21 sealed type 10
PC160LC-7
PC200-7
PC200LC-7
PC220-7
PC220LC-7
Nihon denso, 24V, 4.5kW 8.4
SAA6D102E-2 PC228US-3 sealed type 10
PC228USLC-3
PC270-7
WA200-5, WA200PT-5
WA250-5, WA250PT-5
BR120T-1
11-66 102 SERIES

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STRUCTURE AND FUNCTION STARTING MOTOR
With separate safety relay (5.5 kW)

1. Pinion gear 8. Internal connection diagram

2. Magnetic switch 8A. Relay
3. Starting motor assembly 8B. Starting switch
4. Warning plate (For jump start prohibition) 8C. Battery
5. Jump start protective cover 8D. 30 (Terminal B)
6. 50 (Terminal C) 8E. 50 (Terminal C)
7. 30 (Terminal B)
Engine Machine model Type Specification No. of pinion teeth Weight (kg)
D31EX-21, D31PX-21
SAA4D102E-2 D37EX-21, D37PX-21 Nihon denso,
24V, 5.5kW 10 10.5
D39EX-21, D39PX-21 sealed type
WA150-5
PC220-6 Nihon denso,
SA6D102E-1 24V, 5.5kW 10 10.5
WA300-3 sealed type
PC200-7, PC200LC-7
PC220-7
PC228US-3, PC228USLC-3
PC270-7 Nihon denso,
SAA6D102E-2 BR120T-1, BR380JG-1 sealed type 24V, 5.5kW 10 10.5
WA320-5
GD555-3A, 3C
PC308USLC-3
102 SERIES 11-66-1

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Performance test criteria ............................. 12-52 COMPONENTS
Troubleshooting defective actuation of Testing carbon deposit in air
feed pump (diaphragm type) .................... 12-54 compressor .. . .. . .. .. . .. .. . .. . . .. . .. . . . .. . .. . . . . . .. . .. . .. . . . 12-92
Testing feed pump ................................... 12-54 Testing air leakage from air compressor . .. . 12-93
Test 1: Testing output pressure.. ............. 12-54 Testing air governor, unloader valve . .. . . .. . . . 12-94
Test 2: Testing flow .................................. 12-55
Troubleshooting defective actuation of ELECTRICAL COMPONENTS
feed pump (piston). .................................... 12-56 Testing battery .............................................. 12-97
Test 1: Testing output pressure.. ............. 12-57 Testing battery terminal connections.. ....... 12-98
Test 2: Testing flow .................................. 12-58 Testing starting circuit.. ................................ 12-98
Testing air inside fuel system ...................... 12-61 Testing battery relay ................................ 12-98
Testing water separator, fuel filter .............. 12-62 Testing starting switch.. ......................... 12-l 00
Troubleshooting failure of fuel Testing starting motor and magnetic
injection pump (Bosch VE, Lucas CAV) .... 12-64 switch .................................................... 12-101
Defective actuation of governor ............. 12-65 Testing drop in cranking speed.. ........... 12-103
Stroke of fuel control lever and Testing alternator ....................................... 12-104
adjustment ............................................. 12-65 Abnormal display of charge lamp.. ...... 12-105
l Lucas CAV adjustment screw .............. 12-65 Abnormal actuation of charging
l Bosch VE adjustment screw ................ 12-66 system .................................................. 12-l 06
Manual shut-off lever .............................. 12-66 Testing oil pressure switch and
Timing propulsion angle mechanism ..... 12-67 water temperature sensor ....................... 12-107
Electrical shut-off valve ........................... 12-67 Testing oil pressure switch.. .................. 12-107
Delivery valve (Lucas CAV) ..................... 12-69 Testing water temperature sensor ........ 12-108
Troubleshooting fuel injection pump Testing white smoke .................................. 12-109
(Bosch A, Zexel A) ........................................ 12-70 Normal actuation of intake heater
Testing high-pressure fuel piping ............... 12-70 system .................................................. 12-109
Testing fuel injection nozzle ........................ 12-71 Testing intake heater.. ................................ 12-1 IO
Testing fuel drain piping .............................. 12-73 Testing preheating cycle.. ...................... 12-111
Bleeding air from fuel system ..................... 12-73
Bleeding air from low pressure circuit PERFORMANCE TEST
and fuel filter ........................................... 12-74 Side view of engine.. .................................. 12-112
Bleeding air from fuel injection pump ... 12-74 Outline of engine performance test.. ........ 12-114
Bleeding air from high-pressure Blow-by measurement and
circuit ...................................................... 12-75 replacement table .................................... 12-115
Adjusting fuel injection timing.. .................. 12-75 Engine dynamometer ................................ 12-116
Adjusting fuel injection timing Installing engine ..................................... 12-116
for Bosch VE ........................................... 12-78 Procedure for running in engine .......... 12-123
Adjusting fuel injection timing Engine performance test.. ..................... 12-126
for Lucas CAV ......................................... 12-79 Engine paintwork ....................................... 12-128
Adjusting low idling speed
(Bosch VE, Lucas CAV) ............................... 12-80 STANDARD VALUE TABLE FOR TESTING,
Replacing fuel injection nozzle.. .................. 12-80 ADJUSTING, AND TROUBLESHOOTING . . 12-202
TROUBLESHOOTING OF ENGINE .. . . . .. . . . . . 12-251
COOLING SYSTEM
Troubleshooting defective actuation
of cooling system . . .. ... . . . .. . . .._.................. 12-84
Troubleshooting . . .. . .. . .. . . . . . .. . .. . . . .. . . . . . .. . . . . .. . 12-84
Radiator cap . .. .. . .. . . . .. . ..._........................... 12-86
Water pump . .. . .. .. . . . . . . . .. .. . . . .. . .. . . . .. . . . . . ... .. . .. . 12-87
Radiator, fan, and radiator shutter . . .. . .. . . . 12-88
Thermostat . .. . . . .. . . . . . .. . . . .. . .. ... . . . .. .. . . . . .. .. . .. . . . 12-90
Water temperature gauge,
fuel gauge, overload . .. . .. . . .. . . .. . . . . .. . . . . . .._. 12-91
12-2 102 SERIES

@
TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
102-2
Engine model Pump assembly No. Engine serial No. Applicable machine Page
6737-71-1110 D39EX-21, D39PX-21 12-50-67
6737-71-1120 D31EX-21, D31PX-21 12-50-68

SAA4D102E-2
6737-71-1130 D37EX-21, D37PX-21 12-50-69
6737-71-1140 WA150-5 12-50-70
6738-71-1110 PC200, LC-7, PC228US, USLC-3 12-50-71
6738-71-1130 BR120T-1 12-50-72
6738-71-1150 WA320-5 12-50-73
SAA6D102E-2 6738-71-1160 WA250-5, WA250PT-5 12-50-74
6738-71-1170 WA200-5, WA200PT-5 12-50-76
6738-71-1210 PC220-7, PC220LC-7 12-50-77
6738-71-1310 PC270-7, PC308USLC-3 12-50-75
102 SERIES 12-49-2

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Injection Pump Assembly Number Applicable Machine Applicable Engine

6737-71-1110 (101405-3250)
Model Serial No. Model Serial No.
( ): Injection Pump Manufacture's part No.
D39EX-21 SAA4D102E-2
Injection Injection Pump
Pump Type Manufactuer D39PX-21
BOSCH automotive
PES-A system
Injection Pump Specification Engine Specification

Flywheel horsepower
Rotating direction Clockwise (kw{HP)/rpm} 74{99}/2,200 (Gross)
Injection order 1–3–4–2 Maximum torque (Nm{kgm)/rpm} 441{45}/1,300 (Gross)
Injection interval 89˚ 30' – 90˚ 30' High idling speed (rpm) 2,350 – 2,450
Plunger prestroke (mm) 2.45 – 2.55 Low idling speed (rpm) 800 – 850
Delivery valve 3 Pump tester capacity
retraction volume (mm /st) 59
for Service standard Motor: 7.5 kW
Calibration Standard ( ) : Injenction pump manufacture's part number

Conditions Service standard Manufacturer standard
• Service standard Nozzle & Nozzle holder part No. (105780 – 8140) (105158 – 5010)
indicates data
using calibration Nozzle part No. (105780 – 0000) (105017 – 2910)
test parts. Nozzle holder part No. (105780 – 2080) (105088 – 2000)
• Manufacture Injection pipe
standard is data (mm) 6 ✕ 2 ✕ 600 6 ✕ 1.8 ✕ 600
(Outside dia.x Inside dia.x Length )
for factory Test oil ASTM D975 No.2 diesel fuel or equivalent
test parts.
Oil temperature (˚C) 40 – 50
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 21.6 {220}
Transfer pump pressure (kPa{kg/cm2}) 255 {2.6} 255 {2.6}
Injection volume Service standard (cc/1,000 st) Manufacturer standard (cc/1,000 st)
Rack Rack Pump
point position speed Maximum Maximum
variance variance
(mm) (rpm) Injection volume between Injection volume between
• Rack positions cylinder cylinder
B to E are the ref-
ernce volume A(Basic point) 9.8 1,100 fl 102 – 104 ± 2.5 fl 92.5
when adjusting the
injection volume. B 10.35 650 fl 104 – 108 — fl 116
• Marks fl are C 6.4 420 fl 9 – 11 ± 15 fl 10
average volumes. E 18 – 21 100 fl 50 – 60 — fl 70
Governor perfomance curve Boost compensator performance curve
102 SERIES 12-50-67

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6737-71-1120 (101405-3261)
BOSCH automotive
PES-A system

Flywheel horsepower
Rotating direction Clockwise (kw{HP)/rpm} 59.6{79.9}/2,000 (Gross)
Injection order 1–3–4–2 Maximum torque (Nm{kgm)/rpm} 394.7{40.3}/1,300 (Gross)
Injection interval 89˚ 30' – 90˚ 30' High idling speed (rpm) 2,200 ± 50
Plunger prestroke (mm) 2.45 – 2.55 Low idling speed (rpm) 800 +50
0


indicates data
test parts.
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 22.0 {224.3}
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 9.0 1,000 fl 79 ± 1 ± 2.5 fl 81.5 ± 2.5
when adjusting the
injection volume. B 9.75 650 fl 92.5 ± 2 — fl 106 —
• Marks fl are C Apporox 6.4 420 fl 10 ± 1 ± 15 fl 10 ± 15
average volumes. E 18.0 +30 100 fl 70 ± 5 — fl 92 —
12-50-68 102 SERIES

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6737-71-1130 (101405-3271)
BOSCH automotive
PES-A system

Flywheel horsepower
Injection order 1–3–4–2 Maximum torque (Nm{kgm)/rpm} 420.7{42.9}/1,300 (Gross)
Plunger prestroke (mm) 2.45 – 2.55 Low idling speed (rpm) 800 +50
0


indicates data
test parts.
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 22.0 {224.3}
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 9.7 1,000 fl 93 ± 1 ± 2.5 fl 90 ± 2.5
when adjusting the
injection volume. B 10.35 650 fl 104 ± 2 — fl 114.5 —
• Marks fl are C Apporox 6.4 420 fl 10 ± 1 ± 15 fl 10 ± 15
average volumes. E 18.0 +30 100 fl 70 ± 5 — fl 92 —
102 SERIES 12-50-69

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6737-71-1140 (101405-3340)
WA150-5 SAA4D102E-2
Pump Type Manufactuer
BOSCH automotive
PES-A system

Flywheel horsepower
Injection order 1–3–4–2 Maximum torque (Nm{kgm)/rpm} 408{41.6}/1,300 (Gross)
Plunger prestroke (mm) 2.45 – 2.55 Low idling speed (rpm) 825 ± 50

indicates data
test parts.
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 10.9 1,000 fl 116 ± 1 ± 2.5 fl 102 ± 1 ± 2.5
when adjusting the
injection volume. B (10.9) 650 — — fl (116) ± 2 —
• Marks fl are C 7.4 415 fl 20 ± 1 ± 15 fl 20 ± 1 ± 15
average volumes. D 18.0 +30 100 — — fl (85) —
E 9.35 650 — —
12-50-70 102 SERIES

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Fuel Injection Pump Assembly Number Applicable Machine Applicable Engine

6738-71-1160 (101609-3690)
( ): Fuel Injection Pump Manufacture's part No.
WA250-5 SAA6D102E-2
Fuel Injection Fuel Injection Pump
Pump Type Manufactuer WA250PT-5
BOSCH automotive
PES-A system
Fuel Injection Pump Specification Engine Specification

Flywheel horsepower
Fuel Injection order 1–5–3–6–2–4 Maximum torque (Nm{kgm)/rpm} 627{64}/1,400 (Gross)
Fuel Injection interval 59˚ 30' – 60˚ 30' High idling speed (rpm) 2,200 – 2,300
Calibration Standard ( ) : Fuel Injenction pump manufacture's part number

indicates data
test parts.
Rack Rack Pump
variance variance
(mm) (rpm) Fuel Injection volume between Fuel Injection volume between
B to E are the ref-
ernce volume A(Basic point) 9.7 1,000 fl 100.5 – 102.5 ± 2.5 fl 93.5
when adjusting the
injection volume. B 10.0 700 fl 105 — fl 110
• Marks fl are C 6.5 420 fl 8.5 – 10.5 ± 15 fl 9.5
average volumes. D 8.8 100 fl 31 – 41 — fl 58
E — 100 fl 75 – 85 — fl 105
12-50-74 102 SERIES

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6738-71-1310 (101609-3650)
PC270-7 SAA6D102E-2
Fuel Injection Fuel Injection Pump PC308USLC-3
Pump Type Manufactuer BR380JG-1
BOSCH automotive
PES-A system

Flywheel horsepower
Fuel Injection order 1–5–3–6–2–4 Maximum torque (Nm{kgm)/rpm} 742.4{75.7}/1,500 (Gross)
Plunger prestroke (mm) 2.55 – 2.65 Low idling speed (rpm) 1,025 – 1,075

indicates data
standard is data (mm)
6 ✕ 2 ✕ 600 6 ✕ 1.8 ✕ 750
test parts.
2
Nozzle opening pressure (MPa{kg/cm }) 17.2 {175} 22.0 {224}
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 12.2 1,025 fl 131 – 133 ± 2.5 fl 116
when adjusting the
injection volume. B 12.2 750 fl 130 — fl 127
E — 100 fl 110 – 120 — fl 130
102 SERIES 12-50-75

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6738-71-1170 (101609-3700)
WA200-5 SAA6D102E-2
Pump Type Manufactuer WA200PT-5
BOSCH automotive
PES-A system

Flywheel horsepower
Fuel Injection order 1–5–3–6–2–4 Maximum torque (Nm{kgm)/rpm} 586{59.8}/1,400 (Gross)

indicates data
test parts.
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 9.1 1,000 fl 81 ± 1 ± 2.5 fl 82
when adjusting the
injection volume. B 9.75 700 fl 95.5 — fl 103
• Marks fl are C 6.5 420 fl 9.5 ± 1 ± 15 fl 9.5
average volumes. D 8.55 100 fl 31 ± 5 — fl 54
E — 100 fl 85 ± 5 — fl 105
F 9.75 650 fl 93 ± 3 — fl 105
12-50-76 102 SERIES

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6738-71-1210 (101609-3640)
PC220-7 SAA6D102E-2
Pump Type Manufactuer PC220LC-7
BOSCH automotive
PES-A system

Flywheel horsepower
Fuel Injection order 1–5–3–6–2–4 Maximum torque (Nm{kgm)/rpm} 708{72.3}/1,500 (Gross)
Plunger prestroke (mm) 2.65 – 2.75 Low idling speed (rpm) 1,025 – 1,075

indicates data
standard is data (mm)
6 ✕ 2 ✕ 600 6 ✕ 1.8 ✕ 750
test parts.
2
Nozzle opening pressure (MPa{kg/cm }) 17.2 {175} 21.6 {220}
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 12.0 1,000 fl 127.5 – 129.5 ± 2.5 fl 111.5
when adjusting the
injection volume. B 12.0 750 fl 127.5 — fl 124
E — 100 fl 115 – 125 — fl 145
102 SERIES 12-50-77

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TESTING AND ADJUSTING RUNNING IN STANDARD
102-2
fl The table gives the standard values for machines with fan.
fl The loads for the dynamometer are at an arm's length of 716 mm.
Engine Applicable Order

Item
model machine 1 2 3 4 5 6
D31EX-21 Running time min 2 10 2 3 3

D31PX-21 Engine speed rpm 800 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 49{5} 98{10} 206{21} 397{40}
Flywheel hosepower kW{HP} 0{0} 3.7{5} 8.8{11.8} 25{33.5} 60{80.4}

Load N{kg} 0{0} 49{5} 98{10} 206{21} 451{46}
SAA4D
102E-2
Load N{kg} 0{0} 49{5} 98{10} 206{21} 440{45}
WA150-5 Running time min 2 10 2 3 3

Engine speed rpm 825 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 49{5} 98{10} 206{21} 490{50}
102 SERIES 12-51-10

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TESTING AND ADJUSTING RUNNING IN STANDARD
fl The table gives the standard values for machines with fan.
fl The loads for the dynamometer are at an arm's length of 716 mm.
Engine Applicable Order

Item
model machine 1 2 3 4 5 6
PC200-7 Running time min 2 10 2 3 3

PC200LC-7 Engine speed rpm 1,050 1,000 1,200 1,600 1,950
PC228US-3 Load N{kg} 0{0} 98{10} 245{25} 440{45} 765{78}
PC228USLC-3 Flywheel hosepower kW{HP} 0{0} 7.4{9.7} 22{29} 53{71} 112{150}

PC308USLC-3 Engine speed rpm 1,050 1,000 1,200 1,600 2,050
BR380JG-1 Load N{kg} 0{0} 98{10} 245{25} 440{45} 911{93}
Flywheel hosepower kW{HP} 0{0} 7.4{9.7} 22{29} 53{71} 140{188}

PC220LC-7 Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 98{10} 245{25} 440{45} 882{90}

SAA6D WA200PT-5 Engine speed rpm 825 1,000 1,200 1,600 2,000
102E-2 Load N{kg} 0{0} 98{10} 245{25} 440{45} 628{64}

WA250PT-5 Engine speed rpm 825 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 98{10} 245{25} 440{45} 696{71}

Engine speed rpm 900 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 98{10} 245{25} 440{45} 843{86}
GD555-3A Running time min 2 10 2 3 3

GD555-3C Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 98{10} 245{25} 440{45} 830{85}
12-51-11 102 SERIES

(19)
TESTING AND ADJUSTING PERFORMANCE TEST CRITERIA
PERFORMANCE TEST CRITERIA

fl This table gives the standard values using the JIS compensation
factor.
fl The values in the table are the standard values for machines with
the muffler installed, air cleaner installed, alternator under no
load, and air compressor opened (if installed).
fl The loads for the dynamometer are at an arm's length of 716
mm.
102-1
Engine Applicable Engine Dynamometer

Test item Specifications Speed
model machine (N{kg})
(rpm)
PC60-7 Flywheel horsepower 40.5 kW/1,750 rpm(Net) 1,745 – 1,755 312 – 331
PC70-7 {54.2 HP/1,750 rpm}(Net) {31.8 – 33.8}
PC60-7B Max. torque 245 Nm/1,200 rpm(Net) 1,100 – 1,300 348 – 364
4D102E-1
{25 kgm/1,200 rpm}(Net) {35.5 – 37.1}
High idling speed 1,900 – 2,000 rpm 1,900 – 2,000 —
Low idling speed 1,020 – 1,070 rpm 1,020 – 1,070 —
PC100L-6 {80.9 HP/2,100 rpm}(Net) {39.6 – 41.9}
Max. torque 329 Nm/1,300 rpm(Net) 1,200 – 1,400 466 – 520
{33.5 kgm/1,300 rpm}(Net) {47.5 – 53.0}
Low idling speed 900 – 950 rpm 900 – 950 —
EXCEL {80.9 HP/2,100 rpm}(Net) {39.6 – 41.9}
{33.5 kgm/1,300 rpm}(Net) {47.5 – 53.0}
PC130-6 {85.8 HP/2,200 rpm}(Net) {40.3 – 42.5}
MIGHTY Max. torque 329 Nm/1,300 rpm(Net) 1,200 – 1,400 466 – 520
S4D102E-1 {33.5 kgm/1,300 rpm}(Net) {47.5 – 53.0}
EXCEL {83.8 HP/2,000 rpm}(Net) {42.8 – 45.4}
{33.5 kgm/1,300 rpm}(Net) {47.5 – 53.1}
PC128UU-1 Flywheel horsepower 62.5 kW/1,900 rpm(Net) 1,895 – 1,905 434 – 460
{83.8 HP/1,900 rpm}(Net) {44.3 – 46.9}
Max. torque 329 Nm/1,300 rpm(Net) 1,200 – 1,400 Min. 465
{33.5 kgm/1,300 rpm}(Net) {Min. 47.5}
12-52 102 SERIES

(14)
fl For fuel, use ASTM D975 No. 1 or No. 2.

fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel Fuel Cooling water Lubricating oil Lubricating oil Exhaust

hosepower Torque
consumption temperature temperature pressure temperature
(kW{HP}) (Nm{kgm})
(sec/100cc) (°C) (°C) (kPa{kg/cm2}) (°C)
40.9–43.4 (Gross) — Min. 29.1 75 – 95 90 – 110 340 – 590 Max. 600

{54.8–58.2}(Gross) {3.5 – 6.0}
— 249–261 (Gross) — 75 – 95 90 – 110 — Max. 650
{25.4–26.6}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
61.1–64.8 (Gross) — Min. 19.4 75 – 95 90 – 110 340 – 590 Max. 600

{83.0–88.1}(Gross) {3.5 – 6.0}
— 333–273 (Gross) — 75 – 95 90 – 110 — Max. 650
{34.0–38.0}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
61.1–64.8 (Gross) — Min. 19.7 75 – 95 90 – 110 340 – 590 Max. 600

{83.1–88.1}(Gross) {3.5 – 6.0}
— 333–373 (Gross) — 75 – 95 90 – 110 — Max. 650
{34.0–38.0}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
65.1–68.9 (Gross) — Min. 19.4 75 – 95 90 – 110 340 – 590 Max. 600

{87.2–92.4}(Gross) {3.5 – 6.0}
— 333–373 (Gross) — 75 – 95 90 – 110 — Max. 650
{34.0–38.0}
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
62.9–66.7 (Gross) — Min. 19.0 75 – 95 90 – 110 340 – 590 Max. 600

{ – }(Gross) {3.5 – 6.0}
— 333–372 (Gross) — 75 – 95 90 – 110 — —
{34.0–38.0}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
61.8–65.6 (Gross) — Min. 19.0 75 – 95 90 – 110 340 – 590 Max. 600

{84.0–89.2}(Gross) {3.5 – 6.0}
— Min. 330(Gross) — 75 – 95 90 – 110 — —
{Min. 34}(Gross)
— — — 74 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
102 SERIES 12-53

(17)
factor.
mm.

(rpm)
D31E,S,Q,P-20 Flywheel horsepower 52.2 kW/2,350 rpm(Net) 2,345 – 2,355 309 – 325
D31,PL,PLL-20 {70.0 HP/2,350 rpm}(Net) {31.5 – 33.2}
D31P-20A Max. torque 265 Nm/1,400 rpm(Net) 1,300 – 1,500 402 – 425
{27 kgm/1,400 rpm}(Net) {41.0 – 43.04}
D37E-5 Flywheel horsepower 56.2 kW/2,500 rpm(Net) 2,495 – 2,505 305 – 323
D37P-5A {75.3 HP/2,500 rpm}(Net) {31.1 – 32.9}
{29.9 kgm/1,400 rpm}(Net) {41.0 – 43.4}
PC128US-1 Flywheel horsepower 64.0 kW/2,200 rpm(Net) 2,195 – 2,205 395 – 417
{85.8 HP/2,200 rpm}(Net) {40.3 – 42.5}
{33.5 kgm/1,300 rpm}(Net) {47.5 – 53.0}
S4D102E-1
{85.8 HP/2,200 rpm}(Net) {40.3 – 42.5}
{33.5 kgm/1,300 rpm}(Net) {47.5 – 53.0}
{98.7 HP/2,300 rpm}(Net) {44.0 – 48.4}
{39.5 kgm/1,500 rpm}(Net) {53.5 – 59.1}
GD305A-3 Flywheel horsepower 63 kW/2,500 rpm(Net) 2,495 – 2,505 347 – 367

{85 HP/2,500 rpm}(Net) {35.4 – 37.4}
{35 kgm/1,500 rpm}(Net) {48.2 – 50.9}
12-53-1 102 SERIES

(17)


hosepower Torque
(kW{HP}) (Nm{kgm})
54.3–57.5 (Gross) — Min. 20.9 75 – 95 90 – 110 390 – 590 Max. 550

{73.8–78.2}(Gross) {3.5 – 6.0}
— 287–305 (Gross) — 75 – 95 90 – 110 — Max. 600
{29.3–31.1}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
57.1–60.6 (Gross) — Min. 19.6 75 – 95 90 – 110 340 – 590 Max. 550

{76.5–81.2}(Gross) {3.5 – 6.0}
— 287–305 (Gross) — 75 – 95 90 – 110 — Max. 600
{29.3–31.1}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
65.1–68.9 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{87.3–92.4}(Gross) {3.5 – 6.0}
— 333–373 (Gross) — 75 – 95 90 – 110 — Max. 650
{34.0–38.0}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
65.1–68.9 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{87.3–92.4}(Gross) {3.5 – 6.0}
— 333–373 (Gross) — 75 – 95 90 – 110 — Max. 650
{34.0–38.0}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
74.5–81.9 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650

{100.0–109.8}(Gross) {3.5 – 6.0}
— 376–415 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{38.3–42.3}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
65.0–68.8 (Gross) — 75 – 95 90 – 110 390 – 590 Max. 600

{87.2–92.3}(Gross) {3.5 – 6.0}
— 338–358 (Gross) — 75 – 95 90 – 110 — Max. 650
{34.5–36.5}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.118 {Min.1.2} —
102 SERIES 12-53-2

(17)
factor.
mm.

(rpm)
WA120-3 Flywheel horsepower 67.7 kW/2,400 rpm(Net) 2,395 – 2,405 369 – 390
{90.7 HP/2,400 rpm}(Net) {37.6 – 39.8}
{35.5 kgm/1,600 rpm}(Net) {48.8 – 51.8}
S4D102E-1
WA120-3D Flywheel horsepower 67.7 kW/2,400 rpm(Net) 2,395 – 2,405 369 – 390
{90.7 HP/2,400 rpm}(Net) {37.6 – 39.8}
{35.5 kgm/1,600 rpm}(Net) {48.8 – 51.8}
D41A-6 Flywheel horsepower 59.7 kW/2,400 rpm(Net) 2,395 – 2,405

{80.0 HP/2,400 rpm}(Net)
Max. torque 343 Nm/1,300 rpm(Net) 1,200 – 1,400
6D102E-1
{35.0 kgm/1,300 rpm}(Net)
High idling speed 2,650 rpm 2,600 – 2,700 —
Low idling speed 825 rpm 775 – 875 —
PC200,200LC-6 Flywheel horsepower 99.3 kW/2,000 rpm(Net) 1,995 – 2,005 682 – 721
PC200,200LC-6 {133 HP/2,000 rpm}(Net) {69.5 – 73.5}
HYPER GX Max. torque 563 Nm/1,350 rpm(Net) 1,250 – 1,450 782 – 827
PC210,210LC-6 {57.4 kgm/1,350 rpm}(Net) {79.7 – 84.3}
MIGHTY High idling speed 2,340 – 2,460 rpm 2,340 – 2,460 —
BR200S-1 Low idling speed 1,000 – 1,050 rpm 1,000 – 1,050 —
PC200LC-6 Flywheel horsepower 95.6 kW/2,000 rpm(Net) 1,995 – 2,005 658 – 695
EXCEL {128 HP/2,000 rpm}(Net) {67.1 – 70.9}
PC200-6 Max. torque 545 Nm/1,350 rpm(Net) 1,250 – 1,450 756 – 802
S6D102E-1 CUSTOM {55.6 kgm/1,350 rpm}(Net) {77.1 – 81.8}
CD60RE-1 High idling speed 2,140 – 2,260 rpm 2,140 – 2,260 —
Low idling speed 975 – 1,025 rpm 975 – 1,025 —
PC228UU-1 Flywheel horsepower 95.6 kW/2,000 rpm(Net) 1,995 – 2,005 658 – 695
{128 HP/2,000 rpm}(Net) {67.1 – 70.9}
{55.6 kgm/1,350 rpm}(Net) {77.1 – 81.8}
12-53-3 102 SERIES

(17)


hosepower Torque
(kW{HP}) (Nm{kgm})
66.3–70.4 (Gross) — 75 – 95 90 – 110 390 – 590 Max. 650

{90.2–95.7}(Gross) {3.5 – 6.0}
— 322–364 (Gross) — 75 – 95 90 – 110 — Max. 650
{34.9–37.1}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
66.3–70.4 (Gross) — 75 – 95 90 – 110 390 – 590 Max. 650

{90.2–95.7}(Gross) {3.5 – 6.0}
— 322–364 (Gross) — 75 – 95 90 – 110 — Max. 650
{34.9–37.1}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
67.3–74.3 (Gross) — 80 – 85 80 – 110 580 – 520 Max. 550

{90.2–99.6}(Gross) {2.8 – 5.3}
— 330–366 (Gross) — 80 – 85 80 – 110 — —
{33.7–37.3}(Gross)
— — — 80 – 85 80 – 110 — —
— — — 80 – 85 80 – 110 Min.70 {Min.0.7} —
102–108 (Gross) — Min. 12.0 75 – 95 90 – 110 390 – 590 Max. 650

{138.9–147.1}(Gross) {3.5 – 6.0}
— 559–592 (Gross) — 75 – 95 90 – 110 — Max. 650
{57.0–60.4}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
98.6–104 (Gross) — Min. 12.5 75 – 95 90 – 110 390 – 590 Max. 650

{132–140}(Gross) {3.5 – 6.0}
— 541–574 (Gross) — 75 – 95 90 – 110 — Max. 650
{55.2–58.6}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
98.6–104 (Gross) — Min. 12.5 75 – 95 90 – 110 390 – 590 Max. 600

{132–140}(Gross) {3.5 – 6.0}
— 541–575 (Gross) — 75 – 95 90 – 110 — Max. 650
{55.2–58.6}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
102 SERIES 12-53-4

(17)
factor.
mm.

(rpm)
PC228USLC-1 Flywheel horsepower 95.6 kW/2,000 rpm(Net) 1,955 – 2,005 658 – 695
{128 HP/2,000 rpm}(Net) {67.1 – 70.9}
{55.6 kgm/1,350 rpm}(Net) {77.1 – 81.8}
PC228USLC-2 Flywheel horsepower 95.6 kW/2,000 rpm(Net) 1,995 – 2,005 658 – 695
{128 HP/2,000 rpm}(Net) {67.1 – 70.9}
{55.6 kgm/1,350 rpm}(Net) {77.1 – 81.8}
High idling speed 2,140 – 2,260 rpm —
Low idling speed 1,000 – 1,050 rpm —
D41E, P-6 Flywheel horsepower 78.0 kW/2,400 rpm(Net) 2,395 – 2,405

{105 HP/2,400 rpm}(Net)
Max. torque 461 Nm/1,300 rpm(Net) 1,200 – 1,400
{47.0 kgm/1,300 rpm}(Net)
High idling speed 2,650 rpm 2,600 – 2,700 —
Low idling speed 825 rpm 775 – 875 —
S6D102E-1
WA180-3 Flywheel horsepower 81 kW/2,400 rpm(Net) 2,395 – 2,405 449 – 478
{108 HP/2,400 rpm}(Net) {45.8 – 48.7}
{42.5 kgm/1,600 rpm}(Net) {57.7 – 61.8}

(for EU) {108 HP/2,400 rpm}(Net) {45.8 – 48.7}
{42.5 kgm/1,600 rpm}(Net) {57.7 – 61.8}
WA180PT-3 Flywheel horsepower 81 kW/2,400 rpm(Net) 2,395 – 2,405 449 – 478

{108 HP/2,400 rpm}(Net) {45.8 – 48.7}
{42.5 kgm/1,600 rpm}(Net) {57.7 – 61.8}
Low idling speed 750 – 800 rpm —
12-53-5 102 SERIES

(17)


hosepower Torque
(kW{HP}) (Nm{kgm})
98.6–104.4(Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{132–140} (Gross) {3.5 – 6.0}
— 541–575 (Gross) — 75 – 95 90 – 110 — Max. 650
{55.2–58.6}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
98.6–104.4(Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{132–140} (Gross) {3.5 – 6.0}
— 541–575 (Gross) — 75 – 95 90 – 110 — Max. 650
{55.2–58.6}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
79.0–86.0 (Gross) — 80 – 85 80 – 110 580 – 520 Max. 600

{105–115} (Gross) {2.8 – 5.3}
— 447–474 (Gross) — 80 – 85 80 – 110 — —
{45.6–48.4}(Gross)
— — — 80 – 85 80 – 110 — —
— — — 80 – 85 80 – 110 Min.70 {Min.0.7} —
81–86 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{108–115}(Gross) {3.5 – 6.0}
— 405–434 (Gross) — 75 – 95 90 – 110 — Max. 650
{41.3–44.3}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
81–86 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{108–115}(Gross) {3.5 – 6.0}
— 405–434 (Gross) — 75 – 95 90 – 110 — Max. 650
{41.3–44.3}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
81–86 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{108–115}(Gross) {3.5 – 6.0}
— 405–434 (Gross) — 75 – 95 90 – 110 — Max. 650
{41.3–44.3}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
102 SERIES 12-53-6

(17)
factor.
mm.

(rpm)

{123 HP/2,400 rpm}(Net) {52.0 – 54.8}
{4 kgm/1,600 rpm}(Net) {64.1 – 68.0}
WA250PT-3 Flywheel horsepower 92 kW/2,400 rpm(Net) 2,395 – 2,405 510 – 537

{123 HP/2,400 rpm}(Net) {52.0 – 54.8}
{4 kgm/1,600 rpm}(Net) {64.1 – 68.0}
WA250L-3 Flywheel horsepower 92.6 kW/2,400 rpm(Net) 2,395 – 2,405 535 – 568
(for USA) {124 HP/2,400 rpm}(Net) {54.6 – 57.9}
S6D102E-1 {49.3 kgm/1,600 rpm}(Net) {68.4 – 72.6}
GD521A-1E Flywheel horsepower 104 kW/2,500 rpm(Net) 2,495 – 2,505 561 – 593
{140 HP/2,500 rpm}(Net) {57.2 – 60.5}
{53.5 kgm/1,600 rpm}(Net) {73.4 – 77.7}
JV100WA-2 Flywheel horsepower 99.3 kW/2,000 rpm(Net) 1,995 – 2,005 682 – 721
JV100WP-2 {133 HP/2,000 rpm}(Net) {69.5 – 73.5}
{57.4 kgm/1,350 rpm}(Net) {79.7 – 84.3}
12-53-7 102 SERIES

(17)


hosepower Torque
(kW{HP}) (Nm{kgm})
91.7–96.9 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{124.7–131.7}(Gross) {3.5 – 6.0}
— 450–478 (Gross) — 75 – 95 90 – 110 — Max. 650
{45.9–48.7}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
91.7–96.9 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{124.7–131.7}(Gross) {3.5 – 6.0}
— 450–478 (Gross) — 75 – 95 90 – 110 — Max. 650
{45.9–48.7}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
96–102 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{129–137}(Gross) {3.5 – 6.0}
— 481–510 (Gross) — 75 – 95 90 – 110 — Max. 650
{49.0–52.0}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
105–111 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{140.8–149.3}(Gross) {3.5 – 6.0}
— 515–546 (Gross) — 75 – 95 90 – 110 — Max. 650
{52.5–55.7}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
102–108 (Gross) — Min. 12.0 75 – 95 90 – 110 390 – 590 Max. 650

{137–145}(Gross) {3.5 – 6.0}
— 559–592 (Gross) — 75 – 95 90 – 110 — Max. 650
{57.0–60.4}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
102 SERIES 12-53-8

(17)
factor.
mm.

(rpm)
PC220,LC-6 Flywheel horsepower 118 kW/2,100 rpm(Net) 2,095 – 2,105 769 – 814
PC250HD-1 {158 HP/2,100 rpm}(Net) {78.4 – 83.0}
PC250,LC-6 Max. torque 618 Nm/1,400 rpm(Net) 1,300 – 1,500 861 – 914
{63 kgm/1,400 rpm}(Net) {87.8 – 93.2}
WA300L-3 Flywheel horsepower 114 kW/2,350 rpm(Net) 2,345 – 2,355 657 – 694
(for USA) {153 HP/2,350 rpm}(Net) {67.0 – 70.8}
{62 kgm/1,600 rpm}(Net) {85.5 – 90.5}
PC220,LC-6 Flywheel horsepower 114 kW/2,100 rpm(Net) 2,095 – 2,105 745 – 788
EXCEL {153 HP/2,100 rpm}(Net) {76.0 – 80.4}
SA6D102E-1 {60 kgm/1,400 rpm}(Net) {83.6 – 89.1}
Low idling speed 975 – 1,025 rpm —
AVANCE {153 HP/2,350 rpm}(Net) {67.0 – 70.8}
CUSTOM Max. torque 608 Nm/1,600 rpm(Net) 1,500 – 1,700 838 – 888
{62 kgm/1,600 rpm}(Net) {85.5 – 90.5}
DCA-125SSK Flywheel horsepower 115.5 kW/1,800 rpm(Net) 60Hz 1,795 – 1,805 861 – 914
(DENYO 154.8 HP/1,800 rpm(Net) 60Hz {87.8 – 93.2}
generator) Max. torque — — —
High idling speed Max. 1,890 rpm —

12-53-9 102 SERIES

(17)


hosepower Torque
(kW{HP}) (Nm{kgm})
121–128 (Gross) — Min. 10.7 75 – 95 90 – 110 390 – 590 Max. 600

{162–172}(Gross) {3.5 – 6.0}
— 616–655 (Gross) — 75 – 95 90 – 110 — Max. 650
{62.8–66.8}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 —
116–123 (Gross) — Min. 10.1 75 – 95 90 – 110 390 – 590 Max. 650

{155–164}(Gross) {3.5 – 6.0}
— 600–635 (Gross) — 75 – 95 90 – 110 — Max. 650
{61.2–64.8}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
117.4–124.3 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 600

{157.4–166.6}(Gross) {3.5 – 6.0}
— 586–626 (Gross) — 75 – 95 90 – 110 — Max. 650
{59.8–63.8}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
115.8–122.5 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650

{155.2–164.3}(Gross) {3.5 – 6.0}
— 600–635 (Gross) — 75 – 95 90 – 110 — Max. 650
{61.2–64.8}(Gross)
— — — 75 – 95 90 – 110 — —
— — — 75 – 95 80 – 110 Min.147 {Min.1.5} —
116.3–123.5 (Gross) — — 70 – 90 90 – 110 340 – 490 Max. 650

{155.9–165.6}(Gross) {3.5 – 5.0}
— —
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min.147 {Min.1.5} —
102 SERIES 12-53-10

(17)
factor.
mm.
102-2

(rpm)
D31EX-21 Flywheel horsepower 55.9 kW/2,000 rpm(Net) 2,000 ± 5 361 – 384

D31PX-21 {74.9 HP/2,000 rpm}(Net) {36.9 – 39.2}
Max. torque 384 Nm/1,300 rpm(Net) 1,300 ± 100 520 – 553
{39.2 kgm/1,300 rpm}(Net) {53.1 – 56.4}
High idling speed 2,200 ± 50 rpm 2,200 ± 50 —
Low idling speed 800 +50

0 rpm 800
+50
0 —
D37EX-21 Flywheel horsepower 63.3 kW/2,000 rpm(Net) 2,000 ± 5 409 – 434

D37PX-21 {84.9 HP/2,000 rpm}(Net) {41.7 – 44.3}
Max. torque 412 Nm/1,300 rpm(Net) 1,300 ± 100 548 – 602
{42 kgm/1,300 rpm}(Net) {55.9 – 61.4}

0 rpm 800
+50
0 —
D39EX-21 Flywheel horsepower 70 kW/2,200 rpm(Net) 2,200 ± 5 436 – 462

D39PX-21 {94 HP/2,200 rpm}(Net) {44.5 – 47.1}
Max. torque 434 Nm/1,300 rpm(Net) 1,300 ± 100 584– 647
SAA4D
{44.3 kgm/1,300 rpm}(Net) {59.6 – 66.0}
102E-2 High idling speed 2,400 ± 50 rpm 2,400 ± 50 —

0 rpm 800
+50
0 —
PC160LC-7 Flywheel horsepower 82 kW/2,200 rpm(Net) 2,200 ± 5 493 – 545

{110 HP/2,200 rpm}(Net) {50.3 – 55.6}
Max. torque 431 Nm/1,500 rpm(Net) 1,500 ± 100 577– 640
{44 kgm/1,500 rpm}(Net) {58.9 – 65.3}
Low idling speed 1,050 ± 50 rpm 1,050 ± 50 —
WA150-5 Flywheel horsepower 74.2 kW/2,000 rpm(Gross) 2,000 ± 5 470 – 520

{99.5 HP/2,000 rpm}(Gross) {48 – 53}
Max. torque 408 Nm/1,300 rpm(Gross) 1,300 ± 100 541 – 598
{41.6 kgm/1,300 rpm}(Gross) {55.2 – 61}
Low idling speed 825 ± 50 rpm 825 ± 50 —
Flywheel horsepower
Max. torque
High idling speed
Low idling speed
12-53-21 102 SERIES

(19)

Flywheel Torque Fuel Cooling water Lubricating oil Lubricating oil Exhaust
hosepower consumption temperature temperature pressure temperature
(kW{HP}) (Nm{kgm})
57.8–61.3 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 650

{77.5–82.2}(Gross) {3.5 – 6.0}
— 380–404 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{38.8–41.2}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147{1.5} —
65.6–69.7 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 650

{87.9–93.4}(Gross) {3.5 – 6.0}
— 392–431 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{40–44} (Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147{1.5} —
72.0–76.3 (Gross) — Min. 16.7 75 – 95 90 – 110 340 – 590 Max. 650

{91.5–102.2}(Gross) {3.5 – 6.0}
— 419–464 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{42.7–47.3}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147{1.5} —
81.4–90.0 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 650

{109.1–120.6}(Gross) {3.5 – 6.0}
— 413–459 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{42.2–46.8}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 —
70.5–77.9 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 650

{94.5–104.4}(Gross) {3.5 – 6.0}
— 388–428 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{39.5–43.7}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147{1.5} —
102 SERIES 12-53-22

(19)
factor.
mm.

(rpm)
PC200-7 Flywheel horsepower 107 kW/950 rpm(Net) 1,950 ± 50 740 – 780

PC200LC-7 {143 HP/950 rpm}(Net) {75.6 – 80.8}
PC228US-3 Max. torque 610 Nm/1,500 rpm(Net) 1,500 ± 100 810 – 890
PC228 {62.2 kgm/1,500 rpm}(Net) {82.6 – 90.9}
USLC-3 High idling speed 2,200 ± 30 rpm 2,200 ± 30 —
BR120T-1 Flywheel horsepower 141 kW/2,050 rpm(Gross) 2,050 ± 5 –

{189 HP/2,050 rpm}(Gross) { – }
Max. torque 740 Nm/1,500 rpm(Gross) 1,500 ± 100 –
{75.7 kgm/1,500 rpm}(Gross) { – }

SAA6D
102E-2 PC270-7 Flywheel horsepower 134 kW/2,050 rpm(Net) 2,050 ± 5 871 – 962
PC308 {180 HP/2,050 rpm}(Net) {88.9 – 98.2}
USLC-3 Max. torque 718 Nm/1,500 rpm}(Net) 1,500 ± 100 984 – 1,088
BR380JG-1 {73.3 kgm/1,500 rpm}(Gross) {100.4 – 111}
High idling speed 2,330 +70
_ 30 rpm 2,330 +70
_ 30 —
PC220-7 Flywheel horsepower 125 kW/2,000 rpm(Net) 2,000 ± 5 843 – 931

PC220LC-7 {168 HP/2,000 rpm}(Net) {86 – 95}
Max. torque 684 Nm/1,500 rpm}(Net) 1,500 ± 100 940 – 1,036
{69.8 kgm/1,500 rpm}(Net) {95.9 – 105.7}
High idling speed 2,260 +80
_ 20 rpm 2,260 +80
_ 20 —
12-53-23 102 SERIES

(19)


hosepower Torque
(kW{HP}) (Nm{kgm})
108–115 (Gross) — Min. 75 – 95 90 – 110 340 – 590 Max. 650

{144.9–153.8}(Gross) {3.5 – 6.0}
— 580–640 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{59.1–65.1}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147 {1.5} —
– (Gross) — Min. 75 – 95 90 – 110 340 – 590 Max. 650

{ – }(Gross) {3.5 – 6.0}
— – (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{ – }(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0} —
— — — 75 – 95 80 – 110 Min.147 {1.5} —
134–148 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 675

{179.6–198.6}(Gross) {3.5 – 6.0}
— 705–779 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 675
{71.9–79.5}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147 {1.5} —
126.5–139.7 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 650

{170–187}(Gross) {3.5 – 6.0}
— 673–742 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{68.7–75.7}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147 {1.5} —
102 SERIES 12-53-24

(19)
factor.
mm.

(rpm)

WA200PT-5 {127.7 HP/2,000 rpm}(Gross) {61.6 – 67.9}
{59.8 kgm/1,400 rpm}(Gross) {79.3 – 87.7}

WA250PT-5 {139.5 HP/2,000 rpm}(Gross) {67.3 – 74.3}
{64 kgm/1,400 rpm}(Gross) {84.9 – 93.8}

SAA6D
102E-2 WA320-5 Flywheel horsepower 127 kW/2,000 rpm(Gross) 2,000 ± 5 806 – 890
{170 HP/2,000 rpm}(Gross) {82.2 – 90.8}
{68.5 kgm/1,500 rpm}(Gross) {90.8 – 100.5}
GD555-3A Flywheel horsepower 124.5 kW/2,000 rpm(Gross) 2,000 ± 5 787 – 870

GD555-3C {167 HP/2,000 rpm}(Gross) {80.3 – 88.7}
Max. torque 743 Nm/1,500 rpm(Gross) 1,500 ± 100 984 – 1,088
{75.7 kgm/1,500 rpm}(Gross) {100.4 – 111}
12-53-25 102 SERIES

(19)


hosepower Torque
(kW{HP}) (Nm{kgm})
90.5–100 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 650

{119.6–132.1}(Gross) {3.5 – 6.0}
— 557–615 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{56.8–62.8}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147 {1.5} —
99–109 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 650

{3.5 – 6.0}
— 596–659 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 650
{60.8–67.2}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147 {1.5} —
121–133 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 675

{162.2–178.3}(Gross) {3.5 – 6.0}
— 638–705 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 675
{65.1–71.9}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147 {1.5} —
118–131 (Gross) — — 75 – 95 90 – 110 340 – 590 Max. 650

{160.8–177.7}(Gross) {3.5 – 6.0}
— 705–779 (Gross) — 75 – 95 90 – 110 340 – 590 Max. 675
{71.9–79.5}(Gross) {3.5 – 6.0}
— — — 75 – 95 90 – 110 340 – 590 —
{3.5 – 6.0}
— — — 75 – 95 80 – 110 Min.147 {1.5} —
102 SERIES 12-53-26

(17)
TESTING AND ADJUSTING TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP
TEST 2: TESTING FLOW
A
Caution: To prevent the engine from starting, re-
move the connection of the fuel cut-off
wiring. If there is fuel remaining in the
injection pump, the engine may start.
A
Caution: Do not keep the starting motor rotating
for more than 30 seconds continuously.
If it is run continuously for more than 30
seconds, the starting motor may be dam-
aged.
Remove the connection of the cut-off solenoid wire,

hold the tachometer (799-203-8001) by hand, and
measure the engine speed.
Caution: Leave the cut-off solenoid wire discon

netted and carry out the following check. A,
Remove the connection of the output pressure line
from the fuel feed pump and insert it in a container.
Crank the engine with the starting motor for 30
seconds and measure the flow of fuel from the fuel
feed pump.
Look at the chart and find the correct flow specifi-
cations of the diaphragm type fuel feed pump.
l Draw a vertical line up from the measurement

for the speed.
l Draw a horizontal line from the measurement
for the flow to the point where it intersects
the vertical line for the engine speed.
l If the intersection is above the necessary flow
line, it indicates that the flow is permissible. ml D I APH RAGM [ oz.1
425 14.4
l If the intersection is below the necessary flow 400 13.5
line, it indicates that the flow is not permis- g 375 12.7
sible. > 350 II.9

; 325 ILO
This shows that the actuation of the pump is
> 300 IO.2
defective or that the line resistance is too high. L 275 9.3
o 250 3.5
Example 1 Engine speed: 230 rpm u_ 225 7.6
200 6.0
Passing pump Flow: 260 m.&?
175 5.9
Example 2 Engine speed: 290 rpm 200 225 250 275 300 400
Failing pump Flow: 240 m.@ Engine Cranking SPeed[RPMl fs900nb
12-55
0
TROUBLESHOOTING
DEFECTIVE ACTUATION OF
FEED PUMP (PISTON TYPE)
On the 102 engines, three types of piston pumps

are used for the fuel feed pump.
On 102 engines equipped with a distributor type

fuel injection pump, the part number 3918076 pis-
ton style fuel feed pump can be used as an option.
Caution: Part numbers 3918076 and 3918000 look

the same from the outside. When distin-
guishing these two fuel feed pumps, mea-
sure the free length of the pumping
spring.
The free length of the spring on the 3918076 fuel

fs9spta
feed pump is 53.5 mm.
On the 300 HP marine 102 engine, part number

3918000 piston type fuel feed pump is standard.
Caution: Part numbers 3918076 and 3918000 look

the same from the outside. When distin-
guishing these two fuel feed pumps, mea-
sure the free length of the pumping
spring.
aI
The free length of the spring on the 3918000 fuel
feed pump is 58 mm.
fs9sptb
On the 91 102 engine equipped with the Bosch

P7100 in-line fuel injection pump, part number
On the 94 102 engine equipped with the Bosch
P7100 in-line fuel injection pump, part number
12-56
0
With the piston type fuel feed pump, if the plunger

is moved towards the special lobe of the camshaft,
it is driven mechanically. The fuel feed pump is
equipped with a pumping piston and check valve
which bleeds back and controls the fuel flow when
the engine is shut off.
The normal pressure drop at the fuel filter is a

maximum of 35 kPai0.4 kg/cm21 .
The filter becomes clogged by the dirt in the fuel,
so the drop in pressure increases. If the feed pump
becomes worn, its ability to let fuel flow through
will drop, and the fuel will pass through the dirty
filter. This will cause a drop in the engine output.
Caution: If the filter must be replaced frequently to

allow the engine to display its power to
the full, it means that the feed pump is
worn.
The output of the piston type fuel feed pump can

be tested by the following two methods.
Test 1: Measure the output pressure with an in-line

pressure gauge.
Test 2. Measure the flow
-*
TEST 1: TESTING OUTPUT PRESSURE

OFF
Start the engine and measure the output of the fuel
feed pump with an in-line pressure gauge.
Min. pressure
172kPa{l.8kg/cm21
TEST 2: TESTING FLOW
A
Caution 1: To prevent the engine from starting, re-
move the connection of the fuel cut-off
wiring. If there is fuel remaining in the
injection pump, the engine may start.
Caution 2: Do not keep the starting motor rotat-
ing for more than 30 seconds continu- A
ously. If it is run continuously for more
than 30 seconds, the starting motor
may be damaged.
Remove the connection of the cut-off solenoid wire,

hold the tachometer (799-203-8001)
measure the engine speed.
by hand, and 68
Q
@
Caution: Leave the cut-off of solenoid wire discon-

nected and carry out thefollowing check. A
Rembve the connection of the output pressure line

from the fuel feed pump and insert it in a container.
Crank the engine with the starting motor for 30
seconds and measure the flow of fuel from the fuel
feed pump.

cations of the part number 3918076 fuel feed pump.

for the speed.
30 Seconds
l Draw a horizontal line from the measurement
ml
line, it indicates that the flow is permissible. Opt ion 1 oz.1
426 14.4
l If the intersection is below the necessary flow
400 13.6
line, it indicates that the flow is not permis- g 316 12.7
sible. 2 350 Il.9
This shows that the actuation of the pump is z 326 11.0
defective or that the line resistance is too high. 300 IO.2

3
0 275 9.3
E 250 8.6
Example 1 Engine speed: 240 rpm
226 7.6
Passing pump Flow: 280 m&?
200 6.a
Example 2 Engine speed: 280 rpm 200 226 250 276 300 400
Failing pump Flow: 260 m4? Engine Cranking SPeed[RPMl fs900nl
12-58
0

cations of the part number 3918000 fuel feed pump
used on the 300 HP 102 engine.

for the speed.
l Draw a horizontal linefrom the measurement
for the flow to the point where it intersects 0
Z 275 9.3
l If the intersection is above the necessary flow z 250 8.6
line, it indicates that the flow is permissible. -
k 225 1. 6
line, it indicates that the flow is not permis- 200 6.8
200 225 250 275 300 400
sible.
This shows that the actuation of the pump is Engine Cranking SPeedjRPMl fseOOnd
*
defective or that the line resistance is too high.
Example 1 Engine speed; 240 rpm

Passing pump Flow: 260 mQ ml 1 oz.1
Example 2 Engine speed: 280 rpm 625 21.2
600 20.3
Failing pump Flow: 235 mQ 576 19.6
550 18.6
626 17.8
Look at the chart and find the correct flow specifi- 500 16.9
475 16.1
cations of the part number 3917334fuel feed pump 450 15.3
used on the Bosch P7100 in-line fuel injection 425 14.4
400 13.6
pump. 375 12.7
350 11.9
325 Il.0
l Draw a vertical line up from the measurement 300 IO.2
275 93
for the speed. 200 226 260 275 300 400
l Draw a horizontal line from the measurement Engine Cranking SPeed[RPMl fslOOne
line, it indicates that the flow is permissible.
line, it indicates that the flow is not permis-
sible.
This shows that the actuation .of the pump is
defective or that the line resistance is too high.

Passing pump Flow: 390 mQ
Failing pump Flow: ,360 mQ
If the measured flow is below the line in the above fs900nf

charts, check the resistance at the inlet port before
disassembly and cleaning the fuel feed pump.
The resistance at the inlet port must not exceed
100 mmHg.
If air enters the fuel or the amount of fuel is re-

duced, connect the inlet port of the fuel feed pump
to a temporary supply line and isolate the fuel feed
0a
pump, then carry out the same checks as described
above.
TESTING AND ADJUSTING TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP
TROUBLESHOOTING FAILURE OF FUEL

INJECTION PUMP (BOSCH VE, LUCAS CAV)
The Bosch VE, Lucas CAV DTA, Stanadyne DB4, and
Lucas CAV DPS fuel injection pumps are rotary dis-
tributor pumps. These pumps carry out the fol-
lowing four types of basic function.
Creating the high fuel pressure required for

injection.
Measuring the correct amount of fuel for
each injection cycle.
Sending the measured amount of fuel at
high pressure to each cylinder at the cor-
rect time.
Changing the timing in proportion to the
engine speed.
The fuel injection pump simply uses a single

plunger or rotor to create the necessary high pres-
sure for injection and to send the fuel to the en-
gine.
The Ccylinder Robert Bosch VE fuel injection pump
plunger is as shown in the diagram.
The 4-cylinder Lucas CAV DPA rotor is as shown in I

the diagram.
If the rotor or plunger become worn or damaged,
the pressure and amount of injected fuel will
change, so the engine output will drop. Generally
speaking, when the fuel injection pump injects fuel
from one outlet port, fuel is sent out from all I
outlet ports.
f p902aa
The Stanadyne DB4 fuel injection pump uses a

single rotor fitted with two plunger to create the
high pressure necessary for fuel injection and
sends the fuel to the engine.
The diagram shows the 4-cylinder DB4 rotor.
If the rotor or plunger become worn or dam-
aged, the pressure and amount of injected fuel will
change, so the engine output will drop. Generally
speaking, when the fuel injection pump injects fuel
from one outlet port, fuel is sent out from all
outlet ports. WI
f p902af
12-64
0
TESTING AND ADJUSTING TROUBLESHOOTING FAILURE OF FUEL INJECTION PU’MP
DEFECTIVE ACTUATION OF GOVERNOR

I
The balance between the position of the control
lever and the governor flyweight controls the mea- Governor
Flvweicrht 0-n t ro I
surement of the fuel. The engine output changes
prina
according to the set conditions and the perfor-
mance of the fuel injection pump governor.
To check the performance of the governor, it is nec-
essary to use special equipment operated by a
qualified person. If the seal of the Robert Bosch
VE external adjustment screw is damaged, it will
-
become impossible to adjust the fuel speed.
Balance
fD902ab
The Lucas CAV DPA/DPS fuel pumps use a codified

spring connection to change the governor setting.
If the governor spring connection is not correct,
there will be an adverse effect on the performance.
Adjustment and changing of rating are explained
in this section.
STROKE OF FUEL CONTROL LEVER AND

ADJUSTMENT
032
The amount of injected fuel and the engine speed
and output are controlled by the fuel control lever.
If there is resistance to the stroke of the lever, it will
cause low output. When troubleshooting low out-
put, always check the full stroke of the lever.
fP9lvwa
LUCAS CAV ADJUSTMENT SCREW

There is a lever stopper installed to the idling
adjustment screw for low speed. If the adjustment
screw is used, it is possible to raise the accessory
loading idling speed, or if necessary, to lower the
idling speed. The high-idling screw is sealed, so
any adjustment must be made at an authorized
repair shop and the screw must be resealed.
A - Idling screw
B - High idling screw
f p9assa
12-65
0
BOSCH VE ADJUSTMENT SCREW
A - Idling screw
B - High idling screw
The high-speed adjustment screw on the fuel in-
jection pump is fitted with an all-speed stopper. The
high-speed adjustment screw is sealed. Have any
adjustment made to this screw at an authorized
fuel injection pump service center and reseal the
screw. The high-speed adjustment screw can also
be used to reduce the engine output.
Caution: The fuel control lever of the Robert Bosch

VE fuel injection pump is indexed by the A
pump compensation center shaft. If the
lever is reduced and improperly installed
and adjusted, it will have an adverse ef-
fect on the engine speed and output.
MANUAL SHUT-OFF LEVER
Both fuel injection pumps are fitted with me-

chanical cut-off levers. When the lever is at the
operating position, it is under the force of the
spring. This manual cut-off control is not installed
for every purpose. There is no cable or rod
installed to the lever.
Caution: If the mechanical cut-off lever is moved

even slightly, there will be an effect on
the fuel flow and engine output.
RCIBERT’BDSCH VE fpllvwb
At low output or when it is impossible to stop the

engine with the manual cut-off control, adjust the
length of the cable/rod to compensate so that op-
eration is possible for the whole lever stroke from
one stop position to the other stop position.
LUCAS CAV DPA/DPS fp9lvua
12-66
0
At low output or when it is impossible to stop the

engine with the manual cut-off control, adjust the
length of the cable/rod to compensate so that op-
eration is possible for the whole lever stroke from
one stop position to the other stop position.
TIMING PROPULSION ANGLE

MECHANISM
The adjustment pressure created by the vane type

supply pumps of both fuel injection pumps is used
to advance the timing when the engine speed rises.
The return spring is used to delay the timing when
the engine speed goes down.
‘If the spring breaks, the timing will advance, and
this will cause torque loss, fuel knocking, and over-
heating of the engine.
z
If the timing is delayed, torque loss and high fuel
z I
consumption will occur, and the exhaust will f P902ac
6
change from white smoke to black smoke.
The timing propulsion angle mechanism on the

Lucas CAV DPAfDPS uses a check ball inside the
circuit. However, if this ball is forgotten during
assembly, there will be no timing propulsion angle.
When the timing mechanism is removed in order
to replace the fuel injection pump or repair leak-
age, do not forget to install the check ball again.
f PScbsa
ELECTRICAL SHUT-OFF VALVE
Electrical shut-off valves are installed to the fuel

injection pump. These solenoid-actuated valves
shut off the supply of fuel to the high-pressure
pumping or dividing components.
The Robert Bosch VE shut-off valve is installed to
the top rear of the pump.
r9OOs i
12-67
0
The Lucas CAV DPA/DPS shut-off valve is installed

to the bottom rear of the pump.
12V and 24V operation actuation solenoids and
stop actuation solenoids can be used.
fv9Olsa
The Stanadyne DB4 shut-off valve is under the

governor cover.
12V and 24V operation actuation solenoids and
stop actuation solenoids can be used.
iD900kb
Test the Stanadyne DB4 fuel injection pump shut-

off solenoid by sending electricity to the terminal
and listening for the click.
If a clear click sound can be heard, the solenoid is
being actuated freely.
Caution: Do not check the actuation of the opera-
tion actuation solenoid with the gover-
nor cover removed from the fuel injection
pump.
Using the following values, check the operation
actuation solenoid with an ohmmeter.
Stanadyne DB4 solenoid

Energizing voltage
Voltage
(min)
12 8.8
24 17.6
When the valve on the Lucas CAV DPNDPS pump

opens, a click can be heard.
Using the following values, check the operation
actuation solenoid with an ohmmeter.
CAV solenoid value resistance in ohms

Voltage Energizing voltage (min)
9 at 22°C 9
36 at 22°C 18
12-68
0
When the Robert Bosch valve is actuated, no sound

can be heard, butthe following values are obtained
when checking with an ohmmeter.
Robert Bosch Resistance in

Peak current
shut-off value ohms
12 7.4+0.5 2
24 29.5+2.5 1
Caution: Do not connect the electric wire to the

solenoid when the plunger is removed.
If there is no plunger, the valve may be
damaged.
When there is defective actuation of the valve or

defective wiring of the valve, it is possible to carry
out troubleshooting by removing the plunger and
spring and installing the solenoid again.
fs900ba
Caution: Stop the engine with the mechanical

shut-off lever.
type
A
If the engine is started without the valve, there will
be defective actuation of the valve or wiring.
Use this method where the plunger is removed and
the engine is started when the facilities must be
moved to the place of maintenance.
fv900bb
DELIVERY VALVE (LUCAS CAV)
A delivery tube is installed to the valve. The pur-

pose of the valve is to control the residual pres-
sure in the high-pressure line. If the valve actua-
tion is defective, the residual value will become
unequal, and the engine rotation will not be
smooth or there will be surging.
12-69
0
TESTING AND ADJUSTING TESTING HIGH-PRESSURE FUEL PIPING
TESTING HIGH-PRESSURE
FUEL
Caution: Tighten the high-pressure line securely
and arrange the piping so that the pipes
do not touch each other and do not touch
A
any other component.
The high-pressure fuel line is designed and manu-

factured so that it can send fuel at the injection pres-
sure to the injector. The high-pressure pulse makes
the line expand and contract during the injection
cycle.The diagram shows the high-pressure fuel
line for the distributor type fuel injection pump.
ba
The diagram shows the high-pressure line for the

Bosch P7100 in-line fuel injection pump.
ft9tbsa
Do not weld or substitute the line. Use only parts

with a part number specified for the engine.
The length of the line, internal dimensions, and ri-
gidity are important elements in ensuring that the
engine operates smoothly. Look at the metal tag
to distinguish the part numbers for each line.
Caution: The fuel in the line is at extremely high

pressure, and is dangerous if it leaks. It
can penetrate the skin and cause serious
injury.
When checking for cracks or leakage, use a sheet

of cardboard. Rotate the engine and move the card-
board along the fuel line and check for injected fuel
hitting the cardboard.
If there is leakage of fuel, the engine performance
will drop.
12-70
0
TESTING HIGH-PRESSURE FUEL PIPING
TESTING AND ADJUSTING TESTING FUEL INJECTION NOZZLE
Usually, after replacing the pump or line, there is

air in the fuel line. If there is air in the fueLline, the
engine will not rotate smoothly and there will be
fuel knocking.
Bleed the air from the high-pressure line through

the fitting connecting the injector. Bleed one line
at a time until the rotation of the engine becomes
smooth.
0s
If the air cannot be removed, check for air being
sucked into the pump and supply line.
f s9OOsa
‘N”oszZWl~FUEL INJECTION
Caution: Use only the injector specified for the en-

gine. A Part Number
The engine uses a sealed nozzle and hole-type in-

jector. The injector part number differs according
to the,engine rating. ,With part numbers, the injec-
tor is distingu’ished by the final four digits.
f i90lsa
During the injection cycle, the high pressure from

the fuel injection pump raises the actuation (pop}
pressure and lifts the needle valve inside the injec-
tor.
Fuel is injected into the cylinder. If the injection
pressure goes below the pop pressure, the spring
with shim closes the needle valve and seals the
nozzle after injection.
f iql?Okr
12-71
0
TESTING AND ADJUSTING TESTING FUEL INJECTION NOZZLE
During normal operation, if the needle valve is

lifted up and does not close, or the needle valve
remains open and does not move, there will be
defective ignition in the engine and the output will
drop. If fuel leakage occurs from the open nozzle,
there will be fuel knocking, drop in performance,
smoke, drop in fuel consumption, and irregular
rotation of the engine.
f i9OOkd
To find if any cylinder is misfiring, start the engine,

loosen the fuel line nut for one cylinder, and listen
for any change in the engine speed.
If the engine speed goes down, the injector is send-
ing fuel correctly to the cylinder.
Check each cylinder in turn to locate the injector
which is not working properly.
Before going on to the next injector, check that the
fuel line nut is tightened.
Remove the defective injector and test or replace

it.
If the engine ignition does not return to normal
when the injector is replaced, check the high-pres-
sure line for leakage. Check also for defects in the
delivery valve, such as the fuel draining back to
the fuel injection pump.
If carbon accumulates in the nozzle orifice, the en-

gine output will drop. Remove the spray pattern
and check or replace the injector.
f i9OOsa
12-72
0
BLEEDING AIR FROM FUEL SYSTEM
TESTING AND ADJUSTING ADJUSTING FUEL INJECTION TIMING
BLEEDING AIR FROM HIGH-PRESSURE

CIRCUIT
17 mm, 19 mm
Ia
Caution: The fuel in the line is at extremely high
pressure, and is dangerous if it leaks. It A
can penetrate the skin and cause serious
injury.
Loosen the injector fitting, crank the engine, and

bleed the air from the line. After finishing, tighten
the fitting.
--\
Caution: If fuel is spilled on the hot exhaust mani-

fold, there is danger of fire, so do not A
bleed the air from the engine when it is
hot.
Run the engine and vent the air from one line at a
time until the engine rotates smoothly.
ADJUSTING FUEL INJECTION

TIMING
The timing of the pump and engine is extremely
important. Even if the crankshaft is only slightly
out of time, the following problems will occur with
the pump timing.
1. Drop in starting and output performance

2. Excessive smoke or exhaust gas
3. Drop in fuel consumption
oi9Olvm
The timing of the engine and pump starts with the

timing of the camshaft gear and drive gear for the
fuel injection pump.
The initial stage is the compression top dead cen-
ter (TDC) position for the No. 1 cylinder.
Because of the structure of the engine, the letter
on the gear must be aligned with the mark on the
camshaft gear.
12-75
0
TESTINGAND ADJUSTING ADJUSTING FUEL 1NJECTlONTIMING
Look at the table and check that the timing for the
fuel injection pump and engine is correct. Use the
important parts list (CPL) given in the control parts
list manual in bulletin No. 3379133-20 and the en-
gine data plate. Check if the engine is certified or
not, and if it is certified, check the time and the
relevant authority (EPA or CARB).
According to the above information, look at the next i
E
chart and determine which letter on the fuel injec-
F
tion pump drive gear to align with the camshaft G

gear. I
i t9OOaa
Caution: It is unnecessary to align the timing mark
on the Nihon Denso EP-9 and Bosch P7100
drive gear.
0
When checking if the timing of the fuel injection
pump is correct, check the alignment mark on the a
pump flange and gear flange.
Caution: The pump timing is advanced or retarded

(depending on the direction of rotation)
by 1” for every 1 mm from the timing
mark.
The Lucas CAV DPA, DPS, Stanadyne DB4, Bosch

VE fuel injection pumps are all equipped with a
device to lock the pump shaft at the position for
the No. 1 cylinder top dead center. Use a new part
or an adjusted fuel injection pump where the shaft
enters this position.
At the injection point, align the key groove on the

shaft with the hash mark on the seal housing indi-
cated in the diagram with the delivery valve that
receives the injection.
Caution: The mark shown in the diagram is simply

for reference. It must not be used to set
the fuel injection pump timing.
12-76
0
A mark is made on the delivery valve of the No. 1

cylinder as shown in the diagram.
4-cylinder =A
6-cylinder = D
Firing order
4-cylinder 6-cylinder
A=1 D=l
B=3 E=5
c=4 F=3
D=2 A=6
B=2 f POpssa
c=4
An engine timing mark for determining the top

dead center (TDC) position of the No. 1 cylinder is
made on the engine.
z Caution: If the timing pin is aligned at an improper

z
position on the gear housing, it will be-
6
come impossible to check if the pump
timing is correct in the timing procedure.
After positioning the top dead center position of

the No. 1 cylinder correctly, the factory uses the
timing pin and camshaft gear hole to set the tim-
ing pin assembly to the gear housing. If the gear Pin
housing or timing pin assembly are removed, they
must be returned to the same position. For de-
tails, see Section 7-20.
If the position of the timing pin assembly is not
correct, fix the position again. For details, see Sec-
tion 7-20.
-+;,a, Hou sins
cs9aewa
After installing, make a mark on the flange of the

replacement pump in line with the mark on the
gear housing.
During manufacture, after the lock pump is in-

stalled to the engine where the No. 1 cylinder is
set to top dead center, a mark is stamped on the
gear housing and pump flange. After this, if both
marks are aligned, the timing of the pump and
engine will be correct.
Caution: The gear housing and pump flange marks

are different for each engine.
If the position of the plunger of the Robert Bosch

VE fuel injection pump is measured using the spe-
cial indicator, it is possible to check the timing of
the pump. #l
For details, see Section 5-36 “Checking timing TDC
(Bosch VE pump)“.
ADJUSTING FUEL INJECTION TIMING

FOR BOSCH VE
Rotate the crankshaft to TDC.
12 mm
Remove the plug from the end of the pump.

RI
6%
Q
Timing tool (795-799-1270)
Caution: Do not bend the fuel line.
Install the timing indicator. Check that the stroke

A 1 Rotation
of the indicator is sufficient.
It may be necessary to remove some of the fuel
lines from the fuel injection pump in order to in-
stall the timing indicator.
Caution: Make marks for 0.01 mm increase in the

indicator.
0. 50 mm
One rotation of the indicator needle is
equivalent to 0.50 mm. fD9towa
Q-78
0
Until the movement of the indicator needle stops,

block the crankshaft in the opposite direction to
the engine rotation. Set the scale on the indicator
to 0.
Return the crankshaft to TDC and count the num-
berof rotations of the indicator needle. The read-
ing at the point w,here the engine timing pin is
meshed is the amount of plunger lift of the pump
at that point.
13 mm
Rotate the pump with the mounting stud until the 1.5 mm
a mm
indicator gives the correct value for the plunger
r:
lift. The diagram shows examples of the indicator i
75 mm
readings for various values of the plunger lift. *
- -.
Tighten the plunger mounting nut. i- -
@
: i
.lmm
m: 24 NmI2.4 kgm1
.65mm
1.55 mm
32
1.6mm
f PSOOwr
12 mm
Rotate the timing indicator. install the plug.

m: 10 Nm(O.1 kgm)
62
Q
ADJUSTING FUEL INiJECTlON TIMING ($3

,.*
FOR LUCAS CAV
It is possible to check if the Lucas CAV DPA fuel

K
0
injection pump timing is correct by removing the
inspection plate.
Caution: Special facilities at an authorized repair
.shop are necessary for determining ac-
curately the timing of the Lucas CAV DPA
fuel injection pump. However, when car-
rying out troubleshooting or in emergen-
cies, it is enough to rotate the engine
ahd carry out visual checks of the timing
mark alignment.
Explanation of both these checks is given in rela-

tion to replacement of the fuel injection pump. For
details of installing the timing pin housing, the ex-
planation is given in the section on basic engine
components.
I- aP9Plwa
12-79
0
ADJUSTING LOW IDLING SPEED
TESTING AND ADJUSTING REPLACING FUEL INJECTION NOZZLE
ADJUSTING LOW IDLING

SPEED (BOSCH VE, LUCAS CAV)
IO mm
If necessary, loosen the adjustment screw locknut

RI
and adjust the idling speed.
Caution: With the Stanadyne DR4 fuel injection

pump, do not lower the idling speed set A
at the factory.
REPLACING FUEL INJECTION

NOZZLE
Preparatory work:
l Clean the area around the injector.

l Remove the high-pressure fuel supply line.
l Remove the fuel drain manifold.
I- II
Rust penetrant
Caution: lf there is rust on the mounting nut, the

k&l
injector may rotate inside the bore when 'A
the nut is loosened.
If this happens, the injector positioning ball will

gouge a hole in the bore and this will cause seri-
ous damage to the head.
Soak the mounting nut for at least 3 minutes in
rust penetrant.
f i900wd
Brass drift pin, hammer
Hit the injector body with a drift pin and remove

the rust.
1 Z-80
0
TESTING AND ADJUSTING TREPLACING FUEL INJECTION NOZZLE
24 mm box wrench, universal wrench
Hold the injector body with a universal wrench,

then loosen the mounting nut with a 24-mm box
wrench.
f iQhoca
Puller (795-799-I 170)
Remove the injector. If it is difficult to remove the

injector, use an injector puller.
When removing the injector, tap the injector with

the injector puller to move the injector up and
down.
63 f i9OOvc
Brush (795-799-I 140)
Clean the injector nozzle bore.
f i9boea
12-81
0
Install the injector and a new copper sealing

washer.
Use only one copper washer.
Operating hint: If the area between the washer and

injector is coated thinly with clean
15W40 engine oil, the washer will
not fall off during installation.
f i9waaa
Warning: Injectors in early models (before 1991)

are fitted with a g-mm injector tip which
cannot be used on engines assembled 9 mm 7 mm
after 1991. Engines assembled from
1991 use a 7-mm injector tip.
i
.b f i901ab
If a special adapter sleeve is used for the 7-mm

injector tip, a 7-mm injector can be used in the in-
jector hole on the early models (9 mm).
(
Coat the thread of the injector mounting nut and

the area between the top of the nut and the injec-
A7 mm
La .i
f i9OOwf
tor body with rust prevention agent.
f i9nuwa
12-82
0
24 mm deep well socket
Caution: Align the protruding portion of the injec-

tor with the notched portion of the bore.
w: 60 Nm(6.1 kgm)
Caution: With the current Bosch injector, there is

an O-ring on top of the mounting nut.
After tightening the injector, always push
an O-ring into the groove.
fiihdoa
Assemble the fuel drain manifold and high-pres-

sure line.
Loosen the high-pressure fitting of the injector.
17 mm, 19 mm
Caution: The engine must be at the RUN position.

RI
The engine may start, so check that all
A
measures have been taken to ensure
safety. Carry out the normal procedure
for starting the engine.
When starting the engine, bleed air from the line.

Tighten the fitting.
12-83
0
TROUBLESHOOTING DEFECTIVE ACTUATION
TESTING AND ADJUSTING OF COOLING SYSTEM
TROUBLESHOOTING
DEFECTIVE ACTUATION OF
COOLING SYSTEM
104’ c
TROUBLESHOOTING i 220’ FI
The function of the cooling system is to maintain

the specified operating of the engine. Part of the
heat generated by the engine is absorbed by the
cooling water circulating in the cylinder block and
head. The heat absorbed by the cooling water is
dissipated when the cooling water flows through
the radiator. When carrying out troubleshooting
for overheating, do not forget that if there is too ea9eava
much in the oil pan, the friction when the rod jour-
nal enters the oil generates more heat.
If there is more oil than specified, it will result in a
rise in the oil temperature, and the temperature of
the cool water passing inside the oil cooler will also
rise.
The cooling system is designed to use the speci-

fied amount of cooling water. If the cooling water
level is low, the engine will be operated at above
the specified temperature.
Caution: If it is necessary to add water to the cool-

ing system frequently, there is leakage
somewhere in the cooling system. Locate
the cause of the leakage and carry out re-
pairs.
Caution: The cooling water passages in the engine

must be completely filled with cooling A
water.
Air (bubbles) in the cooling water will cause cavi-

tation when the engine is running, and this will
reduce the efficiency of the heat conductivity. If
there are excessive bubbles in the cooling water,
concentrated overheating will occur at one part of
the cylinder head and block, and this will result in
cracking of the head, scoring of the cylinder, and
blowing out from the head gasket. II ra9OObc
12-84
0
When adding water, always vent the air from the

cooling water passage. Vent the air from the clear-
ance at the jiggle pin, and at the opening of the
water filler port and the top radiator hose. For en-
gines with an aftercooler, open the head valve
when adding water, then vent the air.
Caution: The air can be removed properly at a fill-

ing speed of 14 liters (3.5 U.S. gallons) per
minute.
Caution: When adding cooling water, prepare a

50% mixture of anti-freeze and water be-
fore starting. Anti-freeze does not have
the same capacity as water to remove 501 50%
the heat from the engine, so if anti-freeze WATER WATER
is added to the engine first, the engine 50% 50%
will overheat before the water and anti- ANTIFREEZE ANTIFREEZE
freeze have mixed completely.
When operating the engine in areas where the

ambient temperature is above -37”C, use a 50% mix
of water and ethylene glycol anti-freeze and water.
s When operating the engine at temperatures below
g -37”C, we recommend a mixture of 40% water and
6 60% anti-freeze. Never use coolant with a concen-
tration of more than 60% anti-freeze.
Caution: Never use only water as the coolant. If

only water is used, it will cause corrosion, A
and this will result in damage. The small
holes in the head gasket are in places
where it particularly easy for clogging to
occur. These holes act as orifices, and
their size is important. Do not increase
the size of the orifice. If the orifice size
becomes larger, the flow of cooling wa-
ter will become poor and it cannot pre-
vent overheating.
Water causes rust, so the narrow cooling water

passages will become even narrower. In addition,
if only water is used as the coolant for even com-
n
46
\
paratively short intervals, rust will occur in the cup
plug and this will cause leakage of water.
Caution: If engines under heavy load suddenly lose

their cooling water, there will be serious
damage to the piston and the cylinder
bore.
ck9epka
12-85
0
RADIATOR CAP
A B
The cooling system is designed to use a pressure
cap to prevent boiling of the cooling water.
The following caps are specified for the recom-
mended two systems.
System Cap
A.(For standard use) 104°C 103kPa(l5psi)

B. (For light-duty use) 99°C 48kPa(7psi)
ra9OOsa
Use of unsuitable caps or caps with defective func-

tion will cause the cooling water to flow out and
the engine to run at high temperature.
ra9OOvf
04B
If air gets into the cooling water, when the water
becomes hot, it will overflow and flow out. The
heated air will expand and increase the pressure
in the cooling system, so the cap may also fly off.
In the same way, if compressed gas leaking from
the head gasket enters the cooling water, it may
also cause overflow.
ra900vs
-
Both the cooling system and lubricating system

are under considerable pressure when the engine
is running, so if there is leakage between the two
systems, the two fluids may mix. For example, this
may happen at the head gasket or oil cooler. (For
details, see the section on the lubricating system)
Caution: The transmission oil also passes through

the transmission oil cooler in the bottom
tank of the radiator, so it may also leak
into the cooling water.
ra900vh
12-86
0
WATER PUMP
The water pump sucks up cooling water from the

bottom of the radiator, sends it to the engine, and
returns it to the top of the radiator for cooling. If
the flow of water is reduced or stopped, the en-
gine temperature will rise.
0a
The pump is driven by belt from the crankshaft
pulley. An automatic belt tensioner is installed to
prevent the belt from slipping off the pump pulley.
If the tensioner does not work properly, the rota-
tion of the pump impeller will become slower,
and the flow of cooling water will be reduced.
- fa9besa
The flow of cooling water is also reduced by dete-

rioration of the hose to the water pump. Normally,
if the engine is run at low speed, the hose will not
deteriorate. Check the hose when the engine is
running at rated speed.
Caution: Confirm that the engine is at the operat-

ing temperature. The thermostat is fully
open when the operating temperature is
a minimum of 90°C.
oka
If the water pump becomes worn or the actuation

is defective, it cannot send the necessary amount
of cooling water, so the operating temperature of
the engine will rise. However, before checking the
cooling water flow or replacing the pump, consider
other possibilities shown in the list of possible
causes for troubleshooting.
12-87
0
As mentioned in the explanation for the cooling

water system, resistance in the passage may pre-
vent the water from flowing.
I kn9skpa
RADIATOR, FAN, AND RADIATOR

SHUll-ER
033
The air blown against the fins of the radiator by
the fan acts to cool the water sent through the ra-
diator. The dirt on jobsites (bits of paper, dry grass,
pieces of cloth, dust, etc.), may clog the fins and
prevent the flow of air, so the cooling effect of the
radiator will be reduced.
In cases where the fan is driven by a belt, if the belt

slips, the speed of the fan will be reduced, and this
will reduce the cooling effect. Defective actuation
of the automatic belt tensioner is also a problem.
Caution: Check the bearings of the fan hub and

other pulleys to confirm that they are not
causing vibration or slipping of the belt.
0a
With electric fans, if there is a failure in the electri-
cal circuit, the flow of air will be insufficient and
this will lead to a rise in the temperature of the
engine.
Caution: Check that the temperature sensor is work-

ing properly.
fn9OOkb
12-88
0
032
In some cases, a heat-sensitive fan may also be
used. These types of fan are actuated only when it
is necessary to maintain the cooling water at a fixed
temperature. If the fan does not rotate even when
the temperature of the cooling water rises, the
engine will overheat. If the fan does not stop when
the water temperature goes down, the engine will
operate at low temperature.
Caution: Check that the temperature sensor is work-

ing properly.
0s
The shutter is designed to regulate the amount of
air passing through the radiator.
If the shutter is not opened when necessary, the
engine will overheat; if it is not closed when nec-
essary, the flow of air will be excessive and the
engine will overcool.
Caution: Checkthat the temperature sensor is work-

ing properly. Check the control of the air
pressure actuated shutter. Check for leak-
age of air.
fn900kd
A winter front can be used on charge air-cooled

engines, but the design must cover only one part
of the front of the cooling system. With the front
of the air-cooled system, an opening of at least 120
square inches must be made to allow the air to
pass.
ra9OOvi
-
032
If the fan shroud is not suitable or is damaged, the
flow of air will be reduced and the engine will over-
heat.
0
@
Caution: Check that the air is not circulating repeat-

edly. Check that the baffle is not missing.
ra9OOst
12-89
0
THERMOSTAT
The thermostat controls the temperature of the

cooling water. If the water temperature is below
the operating temperature, the cooling water by-
passes the radiator and is sent to the water pump.
When the water temperature reaches a certain
temperature, the thermostat opens, the bypass
closes, and the cooling water is sent to the radia-
to r.
Caution: Never operate the engine without a ther-

mostat installed. If there is no thermo- A
stat, the cooling water will flow through
the bypass, which has less resistance, and
go straight to the pump, so the engine
will overheat.
I thllhsbb
If the thermostat is not suitable or the actuation is

defective, the engine will overheat or overcool.
88’ C (190” FI
/
ec9OOkb
As mentioned in the section on the cooling water,

when adding water to the cooling system, use the
jiggle pin to vent the air.
12-90
0
Vent the air, and when the water filling operation

is completed, use the jiggle pin as a check valve
and set so that no cooling water flows to the pin
hole when the engine is running.
Caution: If there is no jiggle pin, the engine will

overcool.
ec9OOkc
If the jiggle pin blocks the hole, the thermostat will

react to the cooling temperature and open, so the
flow of water to the radiator will be controlled.
wwil t YUIH ecgoo!,

WATER TEMPERATURE GAUGE, FUEL
GAUGE, OVERLOAD
A gauge and sensor are used to measure the tem-

perature of the cooling water.
If the actuation of these is defective, the tempera-
ture display will not be correct.
ea9oaka
Caution: Excessive fuel will cause overheating of

the engine. Check that the fuel pump is
properly adjusted.
12-91
TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM
TESTING AND ADJUSTING TESTING CARBON DEPOSIT IN AIR COMPRESSOR
Caution: If the engine is always under excessive

load, the engine will overheat. A
-T oi9OObc
TESTING CARBON DEPOSIT

IN AIR COMPRESSOR
Stop the engine.
0s
Open the drain valve of the wet tank and release
the compressed air from the line.
Clean the compressor with steam.

Dry it with compressed air.
Remove the air inlet port connection and outlet port

connection from the air compressor.
12-92
0
TESTING CARBON DEPOSIT IN AIR COMPRESSOR
TESTING AND ADJUSTING TESTING AIR LEAKAGE FROM AIR COMPRESSOR
As shown in the diagram, measure the thickness

of the carbon deposit on the inside of the air deliv- ischaree Line
ery line.
Caution: The thickness of the carbon deposit must

not exceed 1.6 mm.
A
Warning: In order to prevent personal injury or
property damage, the air delivery line
rbon Build UP
cP8tbta
must be made of material able to with-
stand high temperature and high pres-
sure. See the instructions from the
manufacturer.
Caution: If the thickness of the carbon deposit ex-

ceeds the specified value, do as follows.
l Remove the air delivery line and clean or re-

place it. See the instructions from the manu-
facturer.
l Remove the unloader components and cylin-
der head, and check.
cP9OOsa
TESTING AIR LEAKAGE FROM

AIR COMPRESSOR
Stop the engine.
Open the drain valve of the wet tank and discharge
the air from the line. When the pressure is re-
leased, close the drain valve.
ca6OOwb
Run the engine and start the air compressor.

Keep the air compressor pumping at between 550
- 690 kPa15.6 - 7.0 kg/cm*}, and use soapy water to
check the following parts for leakage of air.
l Unloader cover gasket

l Unloader pin O-ring
l Air compressor head gasket
If any leakage of air is found, repair the compo- I

nent.
12-93
0
TESTING AND ADJUSTING TESTING AIR GOVERNOR, UNLOADER VALVE
TESTING AIR GOVERNOR,

UNLOADER VALVE
Stop the air compressor.
Remove the air governor hose from the unloader
body.
If the air governor is installed directly to the air
CE
Q
compressor, remove the air governor.
Warning: During this test, the pressure must not

exceed either the maximum permissible A
pressure for the air line on the machine
or 1035 kPaI10.6 kg/cm*}.
If the air compressor does not carry out pumping,

the problem is in the air compressor.
Remove the cylinder head and unloader compo-
nents, and check. For details, see Section 4-02. If
no problem is found when disassembling and
checking the head or unloader components, re-
move and disassemble the compressor to judge
the cause of the problem.
Warning: During this test, the pressure must not

exceed either the maximum permissible A
pressure for the air line on the machine
or 1035 kPaI10.6 kg/cm*}. See the in-
structions from the manufacturer.
Leave the air governor removed and run the en-

gine to check the actuation of the air compressor.
a
0
12-94
0
TESTING AIR GOVERNOR, UNLOADER VALVE
TESTING AND ADJUSTING TESTING AIR GOVERNOR
Install the air governor line to the unloader body,

then tighten.
TESTING AIR GOVERNOR

Run the air compressor continuously.
Remove the accessory air line from the unloader
port of the air governor.
Caution: Do not remove the connection of the line

from the air compressor unloader valve.
c%
Q
Do not remove the reservoir air line from

the air governor. If the governor is in-
stalled to the compressor, do not remove
the governor from the compressor.
If the accessory air line is removed, install a pipe

plug to the air governor unloader port.
If the air compressor stops pumping at the regu-
lated pressure (the air pressure stops rising), there
is leakage in the accessory or accessory air line.
For details of troubleshooting and repair, see the
instructions from the manufacturer.
When the air compressor does not stop pumping

at the regulated pressure (the air pressure contin-
ues to rise), connect the factory regulated air pres-
sure line to the port of the unloader valve.
Caution: If the governor is installed to the compres-

sor, remove the governor.
TESTING AND ADJUSTING TESTING AIR GOVERNOR
0a
Caution: Check that the air pressure gauge is cor-
rect and the condition of the supply line
and fitting is good, then test the pressure.
Test the air pressure gauge with a master gauge of

known precision.
Apply air pressure of 690 kPa(7.0 kg/cm*) to the

unloader port.
If the pumping of the air compressor stops (the air
pressure stops rising), the actuation of the air gov-
ernor is defective, so repair or replace.
If the air compressor continues pumping (the air

pressure continues to rise), the actuation of the
unloader valve is defective, so repair or replace.
Remove the pipe plug from the unloader port used

for the accessory air line. Install the accessory air
line, and tighten.
Connect the line to the unloader valve.
12-96
0
TESTING AIR GOVERNOR
TESTING AND ADJUSTING TESTING BATTERY
0a
Run the engine and check for leakage of air.
TESTING BATTERY
Add distilled water to the battery cells. !.$@
See the instructions from the manufacturer.
0
Caution: Maintenance-free batteries are sealed, so
it is unnecessary to add water. 32
When using a conventional battery (the current

battery is maintenance free), check the specific
gravity of the battery electrolyte in each cell.
For all batteries, including maintenance-free bat-

teries, it is possible to check by measuring the volt- @
age between the positive (+) cable and the engine
block (ground). Note down the voltage.
ea900sa
12-97
0
TESTING BAlTERY
TESTING BAlTERY TERMINAL CONNECTIONS
TESTING AND ADJUSTING TESTING STARTING CIRCUIT
Connect the remote starter, then start the starting

motor and observe the voltage. A
If the voltage is less than IOV DC, charge the bat-
tery. @
If the voltage suddenly drops below 2V DC, replace @
‘the battery.
Replace
Battery
Bat terr
-
TESTING BATTERY TERMINAL

CONNECTIONS
0s
Check the battery terminals visually for looseness,
damage, and corrosion. Repair or replace any dam-
aged cables or terminals.
ea8csoa
If the connection is corroded, remove the cable and

clean the cable and battery terminal with a battery
brush.
CE-
Q
Install the battery cable and tighten it.
Coat the battery terminal with grease to prevent q
\
corrosion.
TESTING STARTING CIRCUIT

TESTING BA-lTERY RELAY
Caution: Always turn the starting switch to the
OFF position and take steps to prevent
electric shock and injury.
Remove the cable connecting the magnetic switch

and starting motor solenoid from the terminal of
the magnetic switch.
Connect the leads of a multimeter (commercially
available) or equivalent equipment to the two large
switch terminals.
12-98
0
Set the multimeter in position and measure the

resistance (ohms).
When the starting switch is turned OFF, the resis-
tance of the multimeter should become infinity.
Turn the starting switch to the START position.
The multimeter reading should show 0 or an ex-
tremely small resistance.
When the starting switch is turned to the START

position, if the multimeter resistance becomes in-
finity, do as follows.
l Turn the starting switch OFF.
l Set the scale on the multimeter to DC volt-
age.
l Connect one of the leads of the multimeter to

the terminal of the magnetic switch marked
with S, and connect the other lead to the
ground.
l Turn the starting switch to the START posi-
tion.
l If the multimeter does not display any volt-
age, there is no problem in the magnetic
switch. For details of this procedure, see
“Checking starting switch”.
l Turn the starting switch to the OFF position.

l Remove the lead from the multimeter, then
connect the magnetic switch to the starting
motor solenoid.
12-99
0
TESTING AND ADJUSTING TESTING STARTING ClRCiJlT
TESTING STARTING SWITCH
Caution: Always turn the starting switch to the

OFF position and take steps to prevent
electric shock and injury.
Remove the cable connecting the starting switch

and magnetic switch (there is an “S” or “START”
mark) from the terminal of the starting switch.
Connect the positive lead of a multimeter (com-
mercially available) or equivalent equipment to the
terminals of the starting switch, and the negative
lead to the chassis or engine ground.
Caution: When the starting switch is turned to the

OFF position, the voltage of the starting
switch terminal becomes 0. If any volt-
age is shown on the meter, the actuation
of the starting switch is defective, so re-
place it.
sb800kd
Turn the starting switch to the START position.

The multimeter will show the voltage in the sys-
tem.
sb8OOks
If there is no voltage, do as follows.
l Turn the starting switch to the OFF position.

l Connect the positive (+I lead of the multim-
eter to the starting switch terminal where
there is a wire connecting the starting switch
to terminal B of the starting switch solenoid.
12-100
0
If the meter shows that there is the system voltage

at the input terminal of the starting switch, there is
a defect in the starting switch, so replace it.
033
If the meter does not display any voltage, there is
no problem in the switch. Check for breakage or
damage in the wiring from the starting switch to
terminal 6 of the starting switch solenoid and in
the wiring from the starting switch solenoid to
the battery.
TESTING STARTING MOTOR AND

MAGNETIC SWITCH
Before starting troubleshooting of the starting

motor, check that there is no corrosion or loose-
ness of the battery terminals.
eaacsoa
STARTING MOTOR SOLENOID

If the starting motor solenoid does not make any
sound, check for looseness in the wiring connec- 32
0
tions.
Using a multimeter (commercially available) set to

the voltage scale.
Check the system voltage at the terminal of the
battery and the starting motor solenoid.
0a
If the multimeter displays the system voltage at
the starting motor battery terminal, check the volt-
age at terminal S of the starting motor solenoid
used to energize the starting motor.
If the multimeter shows the system voltage at ter-
minal S but the starting motor does not start, there
is defective actuation of the starting motor sole-
noid, so replace the starting motor.
If the multimeter does not display the system volt-

age at terminal S, carry out the following checks.
l
Fuse
Voltage applied to ignition switch and mag-
032
netic switch. For details, see “Checking start- @
ing switch and magnetic switch” in this sec-
tion
l Application safety shut-off system
STARTING MOTOR
Energize the starting switch and check the system

voltage at terminal M of the starting motor.
l System voltage: Defective actuation of the

starting motor or unsuitable grounding, so
repair or replace.
l No voltage: Defective actuation of starting
motor solenoid, so replace.
12-102
0
If a sound can be heard from the starting motor

solenoid, turn the switch OFF then use barring to
turn the crankshaft in both directions.
Carry out barring of the crankshaft as follows. -
1. Turn in the direction of rotation of the en-

gine
2. Turn in the opposite direction to the rota-
tion of the engine
3. Turn in the direction of rotation of the en-
gine
When carrying out barring of the crankshaft in Step

3, try to start the engine. If the starting motor cranks
the engine, check for damage to the starting mo-
tor pinion gear and flywheel ring gear.
TESTING DROP IN CRANKING SPEED
Check that the wiring connections are clean, tight-

ened properly, and that they are not damaged.
Check the battery voltage. For details, see “Check-
ing battery”.
0a
To check the starting motor, if the crankshaft does
not rotate, carry out barring to turn the crankshaft
in the direction of rotation of the engine, and check
that there is no problem with the engine or any
defective internal actuation.
12-103
0
TESTING STARTING CIRCUIT
TESTING AND ADJUSTING TESTING ALTERNATOR
If there is no problem with the engine, check the

voltage applied to the starting motor during rota- @
tion. If the voltage in the 12-volt system is less
than 2.4 volts, check that the connections are all
properly tightened. The limit for the 24-volt sys-
tem is 4.8 volts.
If the cables are correct and the drop in voltage
exceeds the limit, replace the starting motor.
0a
If barring of the crankshaft is more difficult than
normal, check if there is any excessive load from
the driven unit and accessories.
TESTING ALTERNATOR
The alternatorterminals are shown in the diagram.
Terminal R (Delco) and terminal W (Bosch) are l/2
of the system voltage and if the tachometer is set
to the generator, use the accessory to actuate.
1 Bosch
033
Failures in the charging system may be displayed
by the indicator lamp or ammeter.
I
es900kb
12-104
0
ABNORMAL DISPLAY OF CHARGE LAMP
0s
Check the normal actuation of the indicator lamp
as shown below.
Engine Switch Lamp Ampere

stop OFF OFF 0
stop ON ON -
Running ON ON +
SWITCH OFF, LAMP ON, ENGINE STOPPED
035
Remove the lamp lead at the starting switch. If the
lamp stays lighted up, there is a short circuit in the
positive (+) wire at the ignition end of the lamp.
es9OOkd
If the lamp goes out, there is a short circuit in the

switch.
I I es900ke
SWITCH ON, LAMP OFF, ENGINE STOPPED

This condition occurs when there is an open cir-
cuit. Check the location of the open circuit. Check
for any blown fuse between the alternator and ig-
nition switch, blown bulbs, failure in the bulb
socket, and open circuit in the No. 1 or “D +” lead
circuit.
I es900kf
SWITCH ON, LAMP ON, ENGINE RUNNING

Check the drive belt and alternator pulley to con-
firm that the alternator is rotating.
l 6% es900wn
-..-
Remove the lead from terminal D+ (Bosch Kl) or

No. 1 and No. 2 (Delco). If the lamp remains on,
there is a short circuit with the ground at the alter-
nator end of the lamp.
If the lamp goes out, replace the alternator.
\Bosc h
ABNORMAL ACTUATION OF CHARGING

SYSTEM
0s
Check the connection of the battery and wiring.
Check for defects in the wiring. Check that the al-
q
ternator or fireproof wall slip connector, battery
connections and all other connections are tightened \
and clean.
12-106
a
TESTING ALTERNATOR
TESTING OIL PRESSURE SWITCH AND
TESTING AND ADJUSTING WATER TEMPERATURE SENSOR
Turn the starting switch ON, connect the leads of

all the wiring harnesses, then connect the voltme-
ter as follows.
A. Connect the wiring from the alternator BAT

(Delco 15SI) or B+ (Bosch Kl) terminal to the
ground.
B. Connect the wiring from the alternator No. 1
(Delco 15SI) to the ground.
C. Connect the wiring from the alternator No. 2
(Delco 15SI) to the ground.
D. Connect the wiring from the alternator B+
I I I ea900vd
(Bosch Kl) to the ground.
0s
If the reading is 0, there is an open circuit between
the alternator connection and the battery.
Locate the open circuit and repair it.
Turn all the accessories OFF, and connect the volt

meter to the battery. Run the engine at a midrange
speed.
042
If the voltage in the 12-volt system is more than
15.5 V, remove the alternator and carry out repairs.
The limit for the 24-volt system is 28 V.
TESTING OIL PRESSURE

SWITCH AND WATER
TEMPERATURE SENSOR
When troubleshooting problems in the oil pressure
switch or water temperature sensor, check for loose
or corroded connections and for broken wires.
TESTING OIL PRESSURE SWITCH
Remove the oil pressure switch, install a gauge,

then start the engine and measure the oil pressure.
Minimum oil pressure:

Low idling:
(from 675 to 725 rpm) 69 kPa10.7 kg/cm*]
High idling: 207 kPaI2.1 kg/cm*}
Caution: The oil pressure switch is set so that it is

actuated when the pressure goes down to
55 kPa(O.6 kg/cm*}.
TESTING OIL PRESSURE SWITCH AND
TESTING AND ADJUSTING WATER TEMPERATURE SENSOR
TESTING WATER TEMPERATURE

SENSOR
Check for continuity. Electricity flows in the sen-

sor if the cooling water temperature goes above
107°C.
12-108
a
TESTING AND ADJUSTING TESTING WHITE SMOKE
TESTING WHITE SMOKE

White smoke shows that there is incomplete com-
bustion of the fuel when the engine is running at
normal temperature.
The intake manifold heater system is not directly

connected to the fuel system, but it observes the
temperature of the air for the engine. The ther-
mistor sends various resistance values to the elec-
trical control module (ECM) or the equivalent. The
ECM controls the “wait-to-start” lamp and heater
solenoid.
The intake manifold heater element is actuated by

both the preheating mode and postheating mode.
l In the preheating mode, the starting switch is

turned to the ON position but the engine does
not start.
l In the postheating mode, the engine is run-
ning.
If the actuation and starting procedure for the in-

take manifold heater system is correct, there will
be no excessive of the starting motor and there
will be a little white smoke in the exhaust gas when
the engine is first started.
NORMAL ACTUATION OF INTAKE HEATER SYSTEM
Preheating cycle time when Post heater cycle generated

Engine intake manifold
starting key is turned ON before when starting key is turned ON
temperature
the crank cycle after crank cycle
Above 15% Osec No

-9-l5°C *lOsec Yes
-I&9°C 15sec Yes.
-26-l 8°C 17 set Yes
Below -26“C 20 set Yes
* On the heater control module/electronic control module with serial number 008000A and below,
there is no preheating cycle in this cycle.
12-l 09
0
TESTING AND ADJUSTING TESTING INTAKE HEATER
TESTING INTAKE HEATER
Check the battery voltage.

Min: 6.5 V
Check the thermistor.

Remove the thermistor.
Turn the starting switch ON.
0a
Caution: The “Wait-to-start” lamp lights UP.
1 n ‘CLICK’
A click can be heard from the solenoid.
I\ ’ ee9OOkh
0@
Wait for 20 seconds.
The click from the solenoid can no longer be heard. ‘CLICK’
The “Wait-to-start” lamp flashes. Se:c!ds
Caution: If the “Wait-to-start”lamp flashes, it indi-

cates an open circuit in the thermistor
wiring. Remove the thermistor and simu-
late this condition.
ee9OOkc
12-110
0
TESTING AND ADJUSTING TESTING INTAKE HEATER
Turn the starting switch OFF.

Connect the thermistor wiring harness.
TESTING PREHEATING CYCLE
Turn the starting switch ON.

The engine should not start.
A click can be heard from solenoid (2).
Caution: If the engine is running, the temperature

is probably more than 15°C.
ee9OOkd
If the preheating time is too long, the “Wait-to-

start” lamp will go out and will not flash.
Set the multimeter scale to DC voltage.
Connect the multimeter lead to the terminal of the
intake manifold heater. Check each terminal.
TESTING AND ADJUSTING OUTLINE OF ENGINE PERFORMANCE TEST
OUTLINE OF ENGINE
PERFORMANCE TEST
The engine test is a combination of the running-
in operation and performance test. The procedure
for the running-in operation is the operating pe-
riod to make it possible to carry out overall finish-
ing and installing of the engine parts. The per-
formance test also provides an opportunity to carry
out final adjustment needed for giving the most
suitable engine performance.
The engine test can be carried out by using an en-

gine dynamometer or chassis dynamometer. If it
is impossible to use a dynamometer, carry out the
engine test by simulating the dynamometer test.
Before starting the test, check the dynamometer.
The dynamometer must have the ability to test the
engine performance when operating at maximum
speed (rpm) and maximum output (full power).
The engine crankcase pressure is frequently

called the engine blow-by, but it is an important
item to indicate if the piston ring finishing and
mounting is correct. If there is sudden variation in
the blow-by, that is, the value exceeds the speci-
fication by more than 50%, it means that there is
some mistake somewhere. Stop the engine test
until the cause is found and correct it.
12-114
0
TESTING AND ADJUSTING BLOW-BY MEASUREMENT AND REPLACEMENT TABLE
BLOW-BY MEASUREMENT
AND REPLACEMENT TABLE
The blow-by is normally recorded in liters/min, but
it is also possible to use a manometer and to as-
semble the components below to measure the
blow-by from the breather tube.
1. Fit a plug in the end of the part which contacts

the shoulder of the tee pipe.
2. Make an orifice in the plug.
(For details of the size of the orifice, see the
blow-by conversion table below.)
3. Connect the other end (the end without the
plug, which does not contact the shoulder of
the tee pipe) to the breather tube.
4. Connect a manometer to the foot of the tee
pipe.
5. Using the blow-by conversion table, convert
the reading of the manometer to Iiters/min.
Blowby conversion table (for orifice of 5.613 mm)
In Hz0 Liter/min In Hz0 Liter/min
1 27 19 121
2 40 20 124
3 49 21 128
4 58 22 131
5 64 23 135
6 71 24 137
7 76 25 140
8 81 26 144
9 86 27 147
10 90 28 150
11 94 29 154
12 98 30 157
13 102 31 160
14 105 32 163
15 109 33 166
16 112 34 169
17 115 35 172
18 118
12-115
0
TESTING AND ADJUSTING ENGINE DYNAMOMETER
ENGINE DYNAMOMETER
INSTALLING ENGINE
Using engine lifting tool part number ST-125, in-

stall the engine to the test stand. Align the center
of the dynamometer and connect it. For details of
the procedure for aligning the center of the engine,
@
see the instructions.
Caution: Check that the capacity of the dynamom-

eter is sufficient to be able to carry out
the test at 100% engine rated horsepower.
If the capacity is not sufficient, adjust the
test procedure to the limits of the dyna- oilltova
mometer.
Install the cooling water temperature sensor.

Minimum gauge capacity: 107°C
Connect the cooling water supply to the cooling

water inlet port connector (I ).
Connect the cooling water return to the cooling
water outlet port connector (2).
Install the drain plug, tighten the water drain valve,
and check that the clamp and fitting are tightened.
Add or fill the radiator with cooling water to the

bottom of the filler neck in the tank.
KL
u
0
@ I
12416
0
Check the engine connections, fittings, plates, and

plugs for leakage of cooling water. Carry out re-
pairs if necessary.
Connect the water manometer to the turbocharger

intake pipe, and test the air resistance.
Caution: Install the manometer connection so that

it is at an angle of 90” to the flow of air in
the straight portion of the pipe, and set
so that the diameter of the pipe is in front
of the turbocharger.
Caution: A vacuum gauge can be used instead of
the water manometer.
Minimum gauge capacity: 760 mmHz0
Connect the mercury manometer to the straight

portion of the exhaust piping close to the turbo-
charger outlet port, and check the exhaust resis-
tance.
Caution: A pressure gauge can be used instead of

the mercury manometer.
Caution: When checking the exhaust resistance on
the automobile engine, cover the hole
at the catalyst inlet end with tape.

\\ ‘/-a- PeSaaha
Connect the lubricating oil temperature sensor to

the position shown in the diagram.
Minimum gauge capacity: 150°C
Connectthe oil pressure sensor to the main oil rifle

in the cylinder block.
Minimum gauge capacity: 1034 kPailO.5 kg/cm21
\t ck900vo
Caution: Before running the engine after assem-

bly, prime the lubricating oil system to A
prevent internal damage.
When using external pressure to prime the lubri-

cating oil system, connect the supply to the tapped
hole in the main oil rifle.
Use a pump that can supply pressure continuously

at 210 kPa(2.1 kg/cm2}. Connect the pump to the
main oil rifle port as shown in the diagram.
Prime the lubricating oil system with clean 15W-
40 oil until the oil pressure is recorded by the gauge.
Remove the oil supply tube and install the plug.
Check if there is time for the oil to drain to the pan,

then measure with the dipstick and add oil to the
high mark for the engine.
la900sa
12-118
0
If it is impossible to use an external pressure pump,

prime the lubricating oil system as follows.
Add oil to the engine to the high level mark on the
dipstick.
I s9OOsa
Remove the oil supply tube from the turbocharger.

Pour 50 - 60 cc of clean 15W-40 oil through the tur-
bocharger oil filler port.
Connect the oil supply tube to the turbocharger.
Caution: If it is tightened too much, the thread will

be distorted and this will damage the seal A
of the filter element.
Add clean 15W-40 oil to the oil filter.

Screw the filter into the filter head fitting until the
gasket contacts the filter head surface.
Tighten the filter according to the instructions.
When checking that the oil pump supplies enough

oil to the engine, first remove the wire from the
fuel injection pump solenoid.
s90lwa
TESTING AND ADJUSTING ENGINE DYNAMOMEiER
AI
Caution: Do not keep the starting motor turning
continuouslv for more than 30 seconds.
If the starting motor overheats it will be
damaged.
Run the engine until the oil pressure gauge indi-

cates the system pressure.
Caution: After running the starting motor for 30

seconds, wait for 2 minutes for the start-
ing motor to cool down.
Caution: If the pressure is not indicated, locate the
problem and correct it before continuing
the test. st8bdba
Let the oil drain to the oil pan, then measure the oil
level with the dipstick.
If necessary, add oil to the high level mark.
I s9OOsa
Add clean 15W-40 oil to the fuel filter gasket.

Fill the fuel filter with clean fuel.
I I I ff8OOwa
Screw the fuel filter into the filter head until the
gasket contacts the filter head surface.
Tighten the filter a further l/2 to 3/4 turns.
12-120
0
Check that the voltage supply matches the fuel

pump solenoid before connecting the wires.
Install the throttle control rod to the fuel pump
throttle lever.
f v900we
If there is no pipe plug or tapped hole in the air

crossover tube, do as follows.
Remove the air crossover tube from the engine.
Cut a threaded hole for a l/8 inch pipe thread in
the crossover tube at the position shown in the dia-
gram.
Clean off all the metal particles stuck to the air
crossover tube.
Install the crossover tube.
When measuring the turbocharge boost amount,

remove the pipe plug from the air crossover tube
and install pressure gauge (795-790-1470) or a pres-
sure gauge.
Minimum gauge capacity: 1905 mmHg
To measure the engine crankcase blow-by accu-

rately, insert a blow-by inspection tool into the
crankcase breather vent.
Connect the water manometer to the blow-by tool.
A pressure gauge can be used instead of the ma-
nometer.

When measuring the resistance of the fuel filter, 4~

connect a vacuum gauge (795-790-1500) to the in- &
take line of the fuel injection pump.
Minimum gauge capacity: 760 mmHg
To make it possible to unload the compressor, con-

nect the compressed air source to unloader (I). In
this air line, put a valve between the compressed
air source and the unloader.
Caution: Load the Cummins air compressor when

carrying out running-in operation of the
engine. Unload the air compressor when
carrying out the engine performance test.
Caution: Install the load of the compressed air
shown in the diagram to outlet port (2)
of the air compressor.
When loading the air compressor, use a steel tube &JB

or high temperature hose (I), and connect air tank @Q
tube to the outlet port of the compressor.
Install air regulator (3) so that it is possible to main-
tain the tank pressure between 345 - 517 5 kPa when
the engine is at low idling and high idling.
Hose temperature (minimum): 260°C
Before installing the wiring, check the voltage rat-

ing of the starting motor.
When using the starting motor and battery, con-
nect the wires to them.
Caution: When using another starting method for

the engine, carry out the necessary con-
nections in accordance with the instruc-
tions.
12-122
0
PROCEDURE FOR RUNNING IN ENGINE
0a
During the running-in period of the engine, use a
testerto detect mistakes in the assembly and make
the necessary final adjustments to the perfor-
mance to match the specifications.
Caution: The times specified in the steps for run-

ning-in the engine shown below are the
minimum values. If necessary, add ex-
tra time at each stage in addition to the
engine idling time.
0a
The measurements of the indicators and gauges
must be observed carefully throughout all stages
of the engine running-in period. For details of the
specification and service limit values, see page 8-
6.
Engine Speed Torque Oi I Pres.
~~~
coo;;;; out Blowdr

i I
L”Tbesm,9 ee8oasd
033
To evaluate the engine performance accurately,
carry out the following additional measurements
at the engine running-in stage.
Intake Manifold
Pressure
(Turbocharger Boost)
es9OOoa
Even if the engine performance matches the speci-

fications, these measurements should be carried
out. If they do not match the specifications, these
measurements may well show the reason for the
problem.
Fuel in Restriction Exh. Back Pres.
Air Inlet Restriction Fuel DrainPres eo9OOwb
12-123
0
A
Caution: Do not keep the starting motor turning
continuously for more than 30 seconds. RT
If the starting motor overheats it will be
damaged.
Crank the engine and observe the oil pressure when

the engine starts. If the engine does not start within
30 seconds, wait for 2 minutes for the starting
motor to cool down, then crank the engine again.
st8bdba
When the engine speed is 700 rpm, the oil pres-

sure must be a minimum of 69 kPai0.7 kgm).
Caution: If the oil pressure is not maintained within

the specified value, stop the engine im-
mediately.
Excessively low oil pressure and exces-
sively high oil pressure will both cause
damage to the engine.
If the oil pressure is not maintained within the stan-

dard value, correct the problem.
Caution: When running in the engine, do not run

the engine at low idling for longer than A
the specified time. If excessive carbon is 3 to 5 Minutes
deposited, it will cause damage to the en-
gine.
Run the engine at approx. 700 rpm for 3 to 5 min-

utes.
I oi200bb
032
Listen for any abnormal noise. Check for leakage
of cooling water, fuel, and oil.
Check also if the engine is running normally over-
all.
Caution: After repairing any leakage or problem

with components, start the engine run-
ning-in operation again.
12-124
0
Operate the throttle to run the engine at 1200 rpm,

and measure the test load at 25% of the torque peak
load.
Run the engine at this speed and load level, and
set the temperature of the cooling water to 70°C.
Check all the gauges and note the readings. Test Load
Caution: Do not go on to the next step until the

normal blow-by rating is reached.
j 160” Fl
Open the throttle to give the speed for the peak

torque, and adjust the load of the dynamometer to
50% of the torque peak load.
Run the engine for 2 minutes at this speed and load Torque Peak
level.
Check all the gauges and note the data. 2x (Test Load)
(50% Rated Load)
2 Minutes
blow-by is stabilized within the specifica-
tion.
oi804vh
Hold the engine speed at the torque peak rpm, and

raise the dynamometer
peak load.
load to 75% of the torque 0a
Run the engine at this speed and load level for 2 Torque Peak
minutes. Check all the gauges and note the read-
ings. 3x (Test Load)
(75% Rated Load)
‘2 Minutes
blow-by is stabilized within the specifi-
cation.
oii304vi
0a
Move the throttle lever to the fully open position
and raise the dynamometer load until the engine
speed reaches the torque peak rpm. Run the en-
gine at this speed and load level for 10 minutes, or
Full Throttle
run the engine until the blow-by is stabilized
Torque Peak
within the specification.
Check all the gauges and note the readings. Max i mum Load
10 Minutes
oi804vj
ENGINE DYNAMOMETER
TESTING AND ADJUSTING ENGINE PAINTWORK
After the engine cools down, stop the engine.
Remove all the test instruments. Remove the en-

gine from the dynamometer.
Caution: If not use permanent antifreeze, When

storing the engine for a short period, the
cooling water must be drained. The po-
sition of the drain is given in the engine
side view.
Prepare the engine according to ENGINE

PAINTWORK (8-08).
ENGINE PAINTWORK
Remove the belt from the engine.
Cover the following parts of the engine.
l Pulley belt surface

l Intake, exhaust ports
l Electric components
l Fuel suction, drain connections
l Exposed fittings, threads, electrical wiring
terminals
Warning: When cleaning with steam, wear protec-

tive clothing, safety glasses, and face
shield. Hot steam may cause serious
burns.
Clean the engine with steam, then dry with com-

pressed air.
Caution: Before painting the engine, check that the

surface of the engine is clean and dry.
12-l 28
0
TESTING AND ADJUSTING ENGINE PAINTWORK
Be careful not to let paint get on the following com-

ponents.
l Date plate
l Valve and injector match marks
l Exhaust manifold
l Turbocharger turbine housing
l Flywheel
l Flywheel housing transmission mounting sur-
face
Paint the engine.

I K-- I
12-129
0
TROUBLESHOOTING
Standard value table for testing, adjusting, and troubleshooting ............................ 12-202
Troubleshooting of engine system (S mode). ............................................................. 12-251
102 SERIES 12-20 I

@
STANDARD VALUE TABLE FOR TESTING,
TESTING AND ADJUSTING ADJUSTING, AND TROUBLESHOOTING
102-2
Engine model SAA4D102E-2
Applicable machine model D31EX-21, D31PX-21 D37EX-21, D37PX-21
Cat- Measurement Standard Permissible Standard Permissible

egory item conditions Unit value value value value
High idling speed rpm 2,200 ± 50 2,200 ± 50 2,200 ± 50 2,200 ± 50

Performance
Engine speed
Low idling speed rpm 800 +50
0 800 +50
0 800 +50
0 800 +50
0
Nessary stating 0ºC (without starting aid) rpm Min. 170 Min. 170 Min. 170 Min. 170
speed -20º (with starting aid) rpm Min. 120 Min. 120 Min. 120 Min. 120
kPa Max. 3.72 7.47 Max. 3.72 7.47

Intake resistance At all speed {mmH2O} {Max. 380} {762} {Max. 380} {762}
Boost pressure At rated flywheel horsepower kPa Min. 93 81 Min. 106 100
{mmHg} {Min. 700} {650} {Min. 800} {750}
Exhaust pressure
At rated flywheel horsepower kPa Min. 120 106 Min. 120 106
Intake, exhaust system
(turbine inlet pressure) {mmHg} {Min. 900} {800} {Min. 900} {800}
Exhaust temperature All speed (20ºC)
(turbine inlet temp.) ºC Max. 650 700 Max. 650 700
Quick acceleration
(low idle → high idle) Max. 4.5 6.0 Max. 4.0 6.0
Bosch
Exhaust gas color At rated flywheel horsepower index Max. 2.0 3.0 Max. 2.0 3.0
High idling speed Max. 1.0 2.0 Max. 1.0 2.0
Valve clearance Intake valve mm 0.25 — 0.25 —

(When engine is hot
or cold) Exhaust valve mm 0.51 — 0.51 —
Engine proper
Oil temperature: 40 – 60ºC MPa Min. 2.41 1.69 Min. 2.41 1.69
Compression pressure {kg/cm2} {Min. 24.6} {17.2} {Min. 24.6} {17.2}
(SAE30 or SAE15W-40)
(engine speed) (rpm)
Blow-by pressure At rated flywheel horsepower kPa Max. 0.49 0.98 Max. 0.49 0.98
(SAE30 or SAE15W-40) (water temp. : Min. 70ºC) {mmH2O} {Max. 50} {100} {Max. 50} {100}
At rated flywheel horsepower kPa

SAE 30 or SAE15 W–40 oil 340 – 590 245 340 – 590 245
{kg/cm2} {3.5 – 6.0} {2.5} {3.5 – 6.0} {2.5}
kPa 290 – 540 206 290 – 540 206
Oil pressure SAE10W oil
Lubrication system
{kg/cm2} {3.0 – 5.5} {2.1} {3.0 – 5.5} {2.1}

(oil temperature :
At low idling kPa
Min. 80ºC) SAE 30 or SAE15 W–40 oil Min. 147 78 Min. 147 78
{kg/cm2} {Min. 1.5} {0.80} {Min. 1.5} {0.80}
kPa Min. 98 69 Min. 98 69
SAE 10W oil {kg/cm2} {Min. 1.0} {0.70} {Min. 1.0} {0.70}
All speed
Oil temperature (Oil in oil pan) ºC 90 – 110 120 90 – 110 120
At continuous rated horsepower

Oil consumption ratio (Ratio for fuel consumption) % Max. 0.2 0.6 Max. 0.2 0.6
+1.4 +1.4
MPa 22 0 18.0 22 0 18.0
system
Fuel injection pressure Nozzle tester {kg/cm2} +15 +15

Fuel
{224 0 } {184} {224 0 } {184}
Fuel injection timing B. T. D. C degree — —

Opening pressure kPa
Cooling system
Radiator pressure valve (Differential pressure) {kg/cm2} — — — —
Fan speed At rated engine speed rpm 1,660 ± 50 1,660 ± 50 1,660 ± 50 1,660 ± 50
Deflection when pushed

Fan belt tension with a force of 60N {6 kg} mm (Auto-tension) — (Auto-tension) —
12-220 102 SERIES

(19)
SAA4D102E-2
WA150-5
Standard Permissible Standard Permissible Standard Permissible Standard Permissible

value value value value value value value value
2,250 ± 50 2,250 ± 50
825 ± 50 825 ± 50
Min. 170 Min. 170

Min. 120 Min. 120
Max. 3.72 7.47

{Max. 380} {762}
Min. 106 93
{Min. 800} {700}
Min. 120 106
{Min. 900} {800}
Max. 650 700
Max. 4.0 6.0
Max. 1.5 2.5
Max. 0.5 1.5
0.25 —
0.51 —
Min. 2.41 1.69

{Min. 24.6} {17.2}
Max. 0.49 0.98

{Max. 50} {100}
340 – 590 245

{3.5 – 6.0} {2.5}
290 – 540 210
{3.0 – 5.5} {2.1}
Min. 147 78
{Min. 1.5} {0.80}
Min. 98 69
{Min. 1.0} {0.70}
90 – 110 120
Max. 0.2 0.6
+1.4
22 0 18.0
+15
{224 0 } {184}
11 ± 1 —
— —
— —
(Auto-tensioner) —
102 SERIES 12-221

(19)
102-2
Applicable machine model D39EX-21, D39PX-21

egory item conditions Unit value value value value
High idling speed rpm 2,400 ± 50 2,400 ± 50

Performance
Engine speed
Low idling speed rpm 800 +50
0 800 +50
0
Nessary stating 0ºC (without starting aid) rpm Min. 170 Min. 170
speed -20º (with starting aid) rpm Min. 120 Min. 120
kPa Max. 3.72 7.47

Intake resistance At all speed {mmH2O} {Max. 380} {762}
Boost pressure At rated flywheel horsepower kPa Min. 133 127
{mmHg} {Min. 1,000} {950}
Exhaust pressure
At rated flywheel horsepower kPa Min. 153 147
(turbine inlet pressure) {mmHg} {Min. 1,150} {1,100}

Exhaust temperature All speed (20ºC)
(turbine inlet temp.) ºC Max. 650 700
Quick acceleration
(low idle → high idle) Max. 4.0 6.0
Bosch
Exhaust gas color At rated flywheel horsepower index Max. 2.0 3.0
High idling speed Max. 1.0 2.0
Valve clearance Intake valve mm 0.25 —

(When engine is hot
or cold) Exhaust valve mm 0.51 —
Engine proper
Oil temperature: 40 – 60ºC MPa Min. 2.41 1.69

Compression pressure {kg/cm2} {Min. 24.6} {17.2}
Blow-by pressure At rated flywheel horsepower kPa Max. 0.49 0.98

(SAE30 or SAE15W-40) (water temp. : Min. 70ºC) {mmH2O} {Max. 50} {100}
At rated flywheel horsepower kPa

SAE 30 or SAE15 W–40 oil 340 – 590 245
{kg/cm2} {3.5 – 6.0} {2.5}
kPa 290 – 540 206
Lubrication system
{kg/cm2} {3.0 – 5.5} {2.1}

(oil temperature :
At low idling kPa
Min. 80ºC) SAE 30 or SAE15 W–40 oil Min. 147 78
{kg/cm2} {Min. 1.5} {0.80}
kPa Min. 98 69
SAE 10W oil {kg/cm2} {Min. 1.0} {0.70}
All speed
Oil temperature (Oil in oil pan) ºC 90 – 110 120

Oil consumption ratio (Ratio for fuel consumption) % Max. 0.2 0.6
+1.4
MPa 22 0 18.0
system
Fuel injection pressure Nozzle tester {kg/cm2} +15

Fuel
{224 0 } {184}
Fuel injection timing B. T. D. C degree 13 ± 1 —

Cooling system
Radiator pressure valve (Differential pressure) {kg/cm2} — —
Fan speed At rated engine speed rpm 1,825 ± 55 —

Fan belt tension with a force of 60N {6 kg} mm (Auto-tension) —
12-221-1 102 SERIES

(19)
PC160LC-7 PC200-7, PC200LC-7 PC228US-3, PC228USLC-3 PC270-7, PC308USLC-3,

BR380JG-1
+70 +70
2,490 ± 50 2,490 ± 50 2,200 ± 30 2,200 ± 30 2,200 ± 30 2,200 ± 30 2,330 _ 30 2,330 _ 30
1,050 ± 50 1,050 ± 50 1,050 ± 25 1,050 ± 25 1,050 ± 25 1,050 ± 25 1,050 ± 25 1,050 ± 25
Min. 170 Min. 170 Min. 170 Min. 170 Min. 170 Min. 170 Min. 170 Min. 170
Max. 3.72 7.47 Max. 3.72 7.47 Max. 3.72 7.47 Max. 3.72 7.47
{Max. 380} {762} {Max. 380} {762} {Max. 380} {762} {Max. 380} {762}
Min. 120 113 Min. 126 113 Min. 126 113 Min. 146 133
{Min. 900} {850} {Min. 950} {850} {Min. 950} {850} {Min. 1,100} {1,000}
Min. 133 127 Min. 120 106 Min. 120 106 Min. 133 120
{Min. 1,000} {950} {Min. 900} {800} {Min. 900} {800} {Min. 1,000} {900}
Max. 650 700 Max. 650 700 Max. 650 700 Max. 675 700
Max. 4.5 6.5 Max. 5.5 7.5 Max. 5.5 7.5 Max. 5.5 7.5
Max. 1.5 2.5 Max. 21.5 2.5 Max. 21.5 2.5 Max. 1.5 2.5
Max. 1.0 2.0 Max. 0.5 1.5 Max. 0.5 1.5 Max. 0.5 1.5
0.25 — 0.25 — 0.25 — 0.25 —

0.51 — 0.51 — 0.51 — 0.51 —
Min. 2.41 1.69 Min. 2.41 1.69 Min. 2.41 1.69 Min. 2.41 1.69
{Min. 24.6} {17.2} {Min. 24.6} {17.2} {Min. 24.6} {17.2} {Min. 24.6} {17.2}
Max. 0.49 0.98 Max. 0.49 0.98 Max. 0.49 0.98 Max. 0.49 0.98
{Max. 50} {100} {Max. 50} {100} {Max. 50} {100} {Max. 50} {100}
340 – 590 245 340 – 590 245 340 – 590 245 340 – 590 245
{3.5 – 6.0} {2.5} {3.5 – 6.0} {2.5} {3.5 – 6.0} {2.5} {3.5 – 6.0} {2.5}
290 – 540 206 290 – 540 210 290 – 540 210 290 – 540 210
{3.0 – 5.5} {2.1} {3.0 – 5.5} {2.1} {3.0 – 5.5} {2.1} {3.0 – 5.5} {2.1}
Min. 147 78 Min. 150 80 Min. 150 80 Min. 150 80

{Min. 1.5} {0.80} {Min. 1.5} {0.80} {Min. 1.5} {0.80} {Min. 1.5} {0.80}
Min. 98 69 Min. 100 70 Min. 100 70 Min. 100 70
{Min. 1.0} {0.70} {Min. 1.0} {0.70} {Min. 1.0} {0.70} {Min. 1.0} {0.70}
90 – 110 120 90 – 110 120 90 – 110 120 90 – 110 120
Max. 0.2 0.6 Max. 0.2 0.6 Max. 0.2 0.6 Max. 0.2 0.6
+1.4 +1.4 +1.4 +1.4

22 0 18.0 22 0 18.0 22 0 18.0 22 0 18.0
+15 +15 +15 +15
{224 0 } {184} {224 0 } {184} {224 0 } {184} {224 0 } {184}
11 ± 1 — 11 ± 1 — 11 ± 1 — 11.5± 1 —
— — — — — — — —
2,024 ± 60 2,024 ± 60 1,690 ± 50 1,690 ± 50 1,690 ± 50 1,690 ± 50 2,110 ± 50 2,110 ± 50
(Auto-tensioner) — (Auto-tensioner) — (Auto-tensioner) — (Auto-tensioner) —
102 SERIES 12-221-2

(19)
WA200-5, WA250-5,
Applicable machine model WA200PT-5 WA250PT-5
egory item conditions Unit value value value vaalue
High idling speed rpm 2,250 ± 50 2,250 ± 50 2,250 ± 50 2,250 ± 50

Performance
Engine speed
Low idling speed rpm 825 ± 50 825 ± 50 825 ± 50 825 ± 50
Nessary stating 0ºC (without starting aid) rpm Min. 170 Min. 170 Min. 170 Min. 170
speed -20º (with starting aid) rpm Min. 120 Min. 120 Min. 120 Min. 120
kPa Max. 3.72 7.47 Max. 3.72 7.47

Intake resistance At all speed {mmH2O} {Max. 380} {762} {Max. 380} {762}
Boost pressure At rated flywheel horsepower kPa Min. 93 80 Min. 120 106
{mmHg} {Min. 700} {600} {Min. 900} {800}
Exhaust pressure kPa Min. 93 80 Min. 120 106
At rated flywheel horsepower
(turbine inlet pressure) {mmHg} {Min. 700} {600} {Min. 900} {800}
Exhaust temperature
(turbine inlet temp.) All speed (20ºC) ºC Max. 650 700 Max. 650 700
Quick acceleration
(low idle Æ high idle) Max. 5.5 7.5 Max. 5.5 7.5
Bosch
Exhaust gas color At rated flywheel horsepower index Max. 2.0 3.0 Max. 1.5 3.0
High idling speed Max. 0.5 1.5 Max. 0.5 1.5
Valve clearance Intake valve mm 0.25 — 0.25 —

(When engine is hot
or cold) Exhaust valve mm 0.51 — 0.51 —
Engine proper
Oil temperature: 40 – 60ºC MPa Min. 2.41 1.69 Min. 2.41 1.69
Compression pressure {kg/cm2} {Min. 24.6} {17.2} {Min. 24.6} {17.2}
Blow-by pressure At rated flywheel horsepower kPa Max. 0.49 0.98 Max. 0.49 0.98
(SAE30 or SAE15W-40) (water temp. : Min. 70ºC) {mmH2O} {Max. 50} {100} {Max. 50} {100}
At rated flywheel horsepower

SAE 30 or SAE15 W–40 oil kPa 340 – 590 245 340 – 590 245
{kg/cm2} {3.5 – 6.0} {2.5} {3.5 – 6.0} {2.5}
kPa 290 – 540 210 290 – 540 210
Lubrication system
{kg/cm2} {3.0 – 5.5} {2.1} {3.0 – 5.5} {2.1}

(oil temperature :
At low idling
Min. 80ºC) SAE 30 or SAE15 W–40 oil kPa Min. 150 80 Min. 150 80
{kg/cm2} {Min. 1.5} {0.80} {Min. 1.5} {0.80}
kPa Min. 100 70 Min. 70 70
SAE 10W oil {kg`/cm2} {Min. 1.0} {0.70} {Min. 0.70} {0.70}
All speed
Oil temperature (Oil in oil pan) ºC 90 – 110 120 90 – 110 120

Oil consumption ratio (Ratio for fuel consumption) % Max. 0.2 0.6 Max. 0.2 0.6
+1.4 +1.4
MPa 22 0 18.0 22 0 18.0
system
Fuel injection pressure Nozzle tester {kg/cm2} +15 +15

Fuel
{224 0 } {184} {224 0 } {184}
Fuel injection timing B. T. D. C degree 11 ± 1 — 10 ± 1 —

Cooling system
Radiator pressure valve (Differential pressure) {kg/cm2} — — — —
Fan speed At rated engine speed rpm — — — —

Fan belt tension with a force of 60N {6 kg} mm (Auto-tension) — (Auto-tension) —
12-222 102 SERIES

(19)
SAA6D102E-2
WA320-5 GD555-3A, PC220-7,

BR120T-1 PC220LC-7
GD555-3C
2,250 ± 50 2,250 ± 50 2,330 ± 50 2,330 ± 50 2,230 ± 50 2,230 ± 50 +80

2,260 _ 20 +80
2,260 _ 20
900 ± 25 900 ± 25 1,050 ± 25 1,050 ± 25 850 ± 50 850 ± 50 1,050 ± 25 850 ± 50
Max. 3.72 7.47 Max. 3.72 7.47 Max. 3.72 7.47 Max. 3.72 7.47
{Max. 380} {762} {Max. 380} {762} {Max. 380} {762} {Max. 380} {762}
Min. 120 106 Min. 146 133 Min. 146 133 Min. 140 133
{Min. 900} {800} {Min. 1,100} {1,000} {Min. 1,100} {1,000} {Min. 1,050} {1,000}
Min. 126 113 Min. 133 120 Min. 140 127 Min. 133 120
{Min. 950} {850} {Min. 1,000} {900} {Min. 1,050} {950} {Min. 1,000} {900}
Max. 675 700 Max. 650 700 Max. 675 700 Max. 650 700
Max. 4.5 6.5 Max. 5.5 7.5 Max. 4.5 5.5 Max. 5.5 7.5
Max. 2.0 3.0 Max. 1.5 2.5 Max. 1.5 2.5 Max. 1.5 2.5
Max. 0.5 1.5 Max. 0.5 1.5 Max. 1.0 2.0 Max. 0.5 1.5
0.25 — 0.25 — 0.25 — 0.25 —

0.51 — 0.51 — 0.51 — 0.51 —
Min. 2.41 1.69 Min. 2.41 1.69 Min. 2.41 1.69 Min. 2.41 1.69
{Min. 24.6} {17.2} {Min. 24.6} {17.2} {Min. 24.6} {17.2} {Min. 24.6} {17.2}
Max. 0.49 0.98 Max. 0.49 0.98 Max. 0.49 0.98 Max. 0.49 0.98
{Max. 50} {100} {Max. 50} {100} {Max. 50} {100} {Max. 50} {100}
340 – 590 245 340 – 590 245 340 – 590 245 340 – 590 245
{3.5 – 6.0} {2.5} {3.5 – 6.0} {2.5} {3.5 – 6.0} {2.5} {3.5 – 6.0} {2.5}
290 – 540 210 290 – 540 210 290 – 540 210 290 – 540 210
{3.0 – 5.5} {2.1} {3.0 – 5.5} {2.1} {3.0 – 5.5} {2.1} {3.0 – 5.5} {2.1}
Min. 150 80 Min. 150 80 Min. 150 80 Min. 150 80

{Min. 1.5} {0.80} {Min. 1.5} {0.80} {Min. 1.5} {0.80} {Min. 1.5} {0.80}
Min. 100 70 Min. 100 70 Min. 100 70 Min. 100 70
{Min. 1.0} {0.70} {Min. 1.0} {0.70} {Min. 1.0} {0.70} {Min. 1.0} {0.70}
90 – 110 120 90 – 110 120 90 – 110 120 90 – 110 120
Max. 0.2 0.6 Max. 0.2 0.6 Max. 0.2 0.6 Max. 0.2 0.6
+1.4 +1.4
22 0 18.0 22 +1.4
0 18.0 22 0 18.0 22 +1.4
0 18.0
+15 +15
{224 0 } {184} {224 +15
0 } {184} {224 0 } {184} {224 +15
0 } {184}
11 ± 1 — 13 ± 1 — 10 ± 0.5 — 11 ± 1 —
— — — — — — — —
— — — — — — 2,060 ± 50 2,060 ± 50
(Auto-tension) — (Auto-tension) — (Auto-tension) — (Auto-tension) —
102 SERIES 12-223

(19)
TROUBLESHOOTING OF ENGINE
(S MODE)
Method of using troubleshooting charts ............................................................................................ 12-252

S- 1 Starting performance is poor (Starting always takes time) ...................................................... 12-256
S- 2 Engine does not start ................................................................................................................... 12-258
(I) Engine does not turn ............................................................................................................. 12-258
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) .................... 12-259
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) .................. 12-260
S- 3 Engine does not pick-up smoothly (Follow-up is poor) ............................................................ 12-261
S- 4 Engine stops during operations.. ................................................................................................ 12-262
S- 5 Engine does not rotate smoothly (Hunting). .............................................................................. 12-263
S- 6 Engine lacks output (or lacks power) ......................................................................................... 12-264
S- 7 Exhaust gas is black ..................................................................................................................... 12-265
S- 8 Oil consumption is excessive (or exhaust gas is blue) ............................................................. 12-266
S- 9 Oil becomes contaminated quickly ............................................................................................ 12-267
S-IO Fuel consumption is excessive ................................................................................................... 12-268
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down ................................. 12-269
S-12 Oil pressure caution lamp lights up (Drop in oil pressure). ...................................................... 12-270
S-13 Oil level rises (Water, fuel in oil) ................................................................................................ 12-271
S-14 Water temperature becomes too high (Overheating) ............................................................... 12-272
S-15 Abnormal noise is made ............................................................................................................. 12-273
S-16 Vibration is excessive .................................................................................................................. 12-274
12-25 1
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLE-

SHOOTING CHARTS
This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without us-
ing troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections @ + @ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in B are items
that can be obtained from the user, depending
on the user’s level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
[Troubleshooting1
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
(e)
ii
12-252
0
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with !, and of these, causes that have a high prob-
ability are marked with T.
Check each of the [Questions] and [Check items] in
turn, and marked the ! or T in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
%I. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with #to use as reference
for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
~2. Use the # in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
Xl Confirm recent repair history
%2 Degree of use Operatred for long period nnn
12-253
0
. Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel
Legend
0 : Possible causes ljudging f Questions and check items)
0 :Most
probable
causes ijudgi om Questions and Check items)
:Possible causes due to le” of use (used for a long period)
gas is excessive I
YI
Blow-by
Engine pickup is poor and combustion is irregular IO
Match marts on fuel injection pump are out of alignment
1 Leakage ofair beweenturbochargerand head, looreclamp 1
hjection pump test shows @at injection amount is incorrect

a
2 When valve clearance is checked directly it is found to be
12-254
0
rll,,
Five causes
Step 1
Clarify the relationship between the three

symptoms in the [Questions1 and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
t ’ ’
-i7
”
Step 2
Add up the total of Oand Bmarks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I) Clogged air cleaner element: 800
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculation in Step 2 show that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
12-255
0
TROUBLESHOOTING S-1
S-1 Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but
engine takes time to start
• Defective electrical system
Causes
• Insufficient supply of fuel
• Insufficient intake of air
• Improper selection of fuel
(At ambient temperature of -10ºC or below,
ASTM D975 No. 2 diesel fuel is used)
t
elem alve sea
fl Battery charging rate
lter
Ambient Charging rate
100 % 90 % 80 % 75 % 70 %
ve, v
ze fi
ent
temperature
r
r
r
e
inde
eate
20°C 1.28 1.26 1.24 1.23 1.22
rain
gau
f val
0°C 1.29 1.27 1.25 1.24 1.23
, cyl
air h
r, st
ump
–10°C 1.30 1.28 1.26 1.25 1.24
ner
act o
filte
ring
clea
ake
• The specific gravity should exceed the value for the
p
cont
feed
fuel
l int
ston
charging rate of 70% in the above table.
a i r
ctive
trica
ged
ged
ged
• In cold areas the specific gravity must exceed the
n pi
Defe
Clog
value for the charging rate of 75% in the above table.
Clog
Clog
Elec
Wor
Confirm recent repair history
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Indicator lamp does not light up

Engine oil must be added more frequently
Replacement of filters has not been carried out according to operation Manual
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Blow-by gas is excessive
Check items
Timing lock on fuel injection pump does not match

Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When compression pressure is measured, it is found to be low

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged

Heater mount does not become warm
Is voltage 26–30V between alternator terminal B and terminal E Yes
with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
ª Use a test stand

12-256 102 SERIES
(17)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black Causes
• Insufficient intake of air
• Improper condition of fuel injection
d)
d
n)
hea
eize
ctio
• Excessive injection of fuel
and
er s
at
pray
inje
e se
lung
rger
ve s
sive
valv
e
ck, p
cha
renc
n tim defecti
xces
and
urbo
p (ra
ent
erfe
( e
r
alve
ing
fler
e
nde
p
lem
zle,
en t
ranc
, int
pum
f
u
of v
noz
u
i
er e
, cyl
t we
on p
ed m
rger
clea
ion
lean
tion
tact
o
e
ring
i
cha
air b
ecti
ject
ject
e
logg
v
con
njec
air c
l
urbo
r inj
a
ston
e in
e in
v
e of
d, c
e
i
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel is being used
Noise of interference is heard from around turbocharger
Dust indicator lamp is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner element is inspected directly, it is found to be
clogged
When compression pressure is measured, it is found to be low
Troubleshooting
Speed does not change when operation of certain cylinders

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust color returns to normal
When control rack is pushed, it is found to be heavy, or
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
102 SERIES 12-265

(19)
13 DISASSEMBLY AND ASSEMBLY
Special tool list ........................................... 13- 6 Removal of fuel injection pump

Special tools for disassembly (Bosch VE, Lucas AV) .......................... .13-27
and assembly ...................................... .13- 6 Removal of fuel injection pump
Special tools for engine ........................ 13- 8 (Bosch A, Zexle A) ................................ 13-27
Special tools for fuel system ................ 13-10 Removal of feed pump
Outline of disassembly and assembly (engine mount type). ............................ 13-30
of engine ............................................... 13-12 Removal of tappet cover.. ..................... 13-30
Outline ..................................................... 13-12 Removal of oil filler port.. ..................... 13-30
Disassembly ........................................... 13-12 Removal of oil cooler.. .......................... .13-30
Assembly ................................................ 13-12 Removal of water inlet ........................... 13-31
Disassembly of engine .............................. .13-13 Removal of oil pan ................................ .13-31
Steam cleaning of engine.. ................... 13-13 Removal of oil pan suction tube .......... 13-31
Removal of starting motor ................... 13-13 Removal of rear seal cover.. ................. 13-32
Weight of engine .................................... 13-13 Removal of camshaft ............................. 13-32
Installation to engine stand .................. 13-13 Removal of tappet.. ................................ 13-34
‘0 Draining oil ............................................. 13-14 Removal of oil pump.. ........................... .13-34
% Removal of rear lifting bracket.. ........... 13-14 Removal of timing pin housing.. .......... 13-35
G Removal of belt ...................................... 13-14 Removal of gear housing ..................... 13-35
Removal of fan pulley.. ......................... -13-15 Removal of balancer ............................. .13-36
Removal of vibration damper, Removal of piston connecting rod.. ..... 13-38
crankshaft pulley .................................. 13-15 Removal of crankshaft .......................... .13-40
Removal of belt tensioner .................... 13-15 Removal of turbocharger
Removal of fan hub.. .............................. 13-16 lubrication drain tube.. ......................... 13-42
Removal of alternator ............................ 13-16 Removal of cylinder block
Removal of thermostat ......................... .13-17 from engine stand ............................... .13-42
Removal of turbocharger Assembly of engine.. .................................. 13-43
(engine with turbocharger). ................ 13-17 Preparation for assembly
Removal of exhaust manifold .............. 13-19 of cylinder block ................................... 13-43
Removal of fuel filter.. ........................... .13-19 Installation of tappet .............................. 13-43
Removal of fuel filter head ................... 13-20 Installation of crankshaft ...................... 13-44
Removal of fuel piping.. ........................ .13-20 Installation of piston and
Removal of dipstick.. .............................. 13-22 connecting rod ..................................... 13-48
Removal of intake manifold cover.. ..... 13-22 Installation of piston and
Removal of after cooler connecting rod assembly :. ................. 13-48
(engine with after cooler) .................... 13-23 Installation of gear housing.. ................ 13-52
Removal of cylinder head cover .......... 13-23 Installation of oil pump.. ....................... .13-53
Removal of fuel injection nozzle .......... 13-23 Installation of camshaft ........................ 13-54
Removal of rocker lever.. ...................... 13-24 Installation of timing pin.. ..................... 13-57
Removal of push rod.. ............................ 13-25 Installation of balancer .......................... 13-60
Removal of cylinder head ..................... 13-25 Installation of rear oil seal .................... 13-64
Removal of front cover ......................... .13-25 Installation of oil pan suction tube ....... 13-65
Removal of water pump ....................... 13-26 Installation of oil pan ............................ .13-66
Removal of flywheel ............................. .13-26 Installation of oil cooler ........................ 13-67
Removal of flywheel housing.. ............. 13-27 Installation of oil filler port ................... 13-67
Removal of components Installation of feed pump.. .................... 13-68
(compressor, hydraulic pump, etc.) ... 13-27 Installation of tappet cover.. ................. 13-68
13-1
0
Installation of fuel injection pump Exhaust group.. ........................................... 13-112
(Bosch A, Zexel A) .................................. 13-69 Disassembly and assembly drawing ... 13-112
Installation of components Outline of exhaust manifold .................. 13-113
(compressor, hydraulic pump, etc.) ..... 13-74 Replacement of exhaust
Installation of flywheel housing ............. .13-75 manifold, gasket ....................................... 13-114
Installation of flywheel.. ........................... 13-75 Removal .................................................. 13-114
Installation of water pump ...................... 13-76 Cleaning and inspection ....................... .13-114
Installation of front cover ........................ 13-76 Installation .............................................. 13-114
Installation of cylinder head ................... .13-78 Replacement of exhaust manifold ......... .13-115
Installation of push rod ............................ 13-79 Removal .................................................. 13-115
Installation of rocker lever ....................... 13-79 Cleaning .................................................. 13-115
Tightening of cylinder head.. .................. .13-81 Installation .............................................. 13-116
Adjusting valve clearance.. ...................... 13-83 Inspection ............................................... 13-116
Installation of fuel injection nozzle .......... 13-85 Replacement of turbocharger.. .................. 13-117
Installation of cylinder head cover .......... 13-86 Removal .................................................. 13-117
Installation of intake manifold cover.. ... 13-86 Installation .............................................. 13-118
Installation of fuel filter head ................. .13-88 Turbocharger mounting stud
Installation of exhaust manifold.. ........... .13-89 (engine with turbocharger) ..................... .13-121
Installation of turbocharger Replacement.. ......................................... 13-l 21
(engine with turbocharger). ................... 13-90 Cylinder block group .................................. 13-122
Installation of thermostat ........................ 13-93 Disassembly and assembly drawing ... 13-122
Installation of crankshaft pulley, Outline of cylinder block group.. .......... .13-125
vibration damper.. .................................. 13-94 Outline of camshaft.. .............................. 13-125
Installation of fan hub .............................. 13-94 Outline of crankshaft.. ............................ 13-125
Installation of belt tensioner.. ................. .13-94 Outline of cylinder block.. ...................... 13-125
Installation of water inlet.. ........... . .......... .13-95 Outline of oil seal ................................... 13-125
Installation of alternator .......................... 13-95 Replacement of front oil seal.. ................. 13-126
Installation of belt.. ................................... 13-96 Removal .................................................. 13-126
Installation of oil filter .............................. 13-97 Cleaning and inspection ....................... .13-127 &
Removal of engine from engine stand .. 13-97 Installation .............................................. 13-127 %
Installation of starting motor.. ................ .13-97 Replacement of rear oil seal .................... 13-129 6
Intake group ............................................. . .... 13-98 Outline of piston ..................................... 13-131
Disassembly and assembly drawing ..... 13-98 Outline of vibration damper.. ............... .13-131
Outline.. ................................................... 13-100 Check list for cylinder block group ........ 13-132
Replacement of turbocharger Cylinder block ............................................. 13-133
(engine with turbocharger) ...................... 13-101 Inspection before disassembly ............ .13-l 33
Removal .................................................. 13-101 Disassembly of cylinder block.. ............ .13-133
Installation .............................................. 13-102 Cleaning of cylinder block ..................... 13-135
Cleaning and inspection ........................ 13-104 Inspection of cylinder block.. ................. 13-138
Replacement of aftercooler, gasket Removal of glaze from cylinder bore.. ... .13-140
(engine with aftercooler) ..................... 13-106 Disassembly ........................................... 13-140
Removal .................................................. 13-106 Inspection ............................................... 13-l 41
Cleaning .................................................. 13-106 Removal of glaze.. .................................. 13-141
Installation .............................................. 13-107 Cleaning .................................................. 13-144
Cleaning and inspection ........................ 13-108 Assembly ................................................ 13-145
Assembly ................................................ 13-108 Removal of glaze from cylinder block.. ... 13-146
Replacement of intake connector.. ........... .13-109 Replacement of plug ................................ 13-149
Removal and installation ....................... 13-109 Removal .................................................. 13-149
Air connector .............................................. 13-109 Cleaning and inspection ........................ 13-149
Cleaning .................................................. 13-109 Installation .............................................. 13-150
Inspection ............................................... 13-109 Replacement of cap .................................. 13-150
Replacement of intake Removal .................................................. 13-150
manifold cover, gasket ............................. 13-109 Cleaning .................................................. 13-151
Removal .................................................. 13-110 Installation .............................................. 13-151
Cleaning .................................................. 13-110 Installation of cap and plug ..................... 13-154
Installation .............................................. 13-110 Installation of camshaft cup .................. 13-156
Air crossover tube ...................................... 13-111 Installation of camshaft bushing.. ........ .13-157
Cleaning .................................................. 13-111 Replacement of dipstick tube ............... .13-158
Inspection ............................................... 13-111 Storing cylinder block.. .......................... 13-159
13-2
0
Crankshaft ................................................... 13-159 Installation .............................................. 13-227
Replacement of main bearing .............. .13-160 Replacement of connecting
Inspection of crankshaft.. ....................... 13-160 rod bearing ........................................... 13-228
Cleaning of crankshaft .......................... .13-165 Removal .................................................. 13-228
Installation of crankshaft ....................... 13-I 65 Cleaning and inspection ........................ 13-230
Placement of crankshaft gear.. .............. 13-166 Installation .............................................. 13-231
Replacement of camshaft and tappet.. ‘13-168 Disassembly of piston
Removal of camshaft ............................. 13-168 connecting rod ..................................... 13-234
Removal of tappet .................................. 13-169 Cleaning of piston, pin,
Inspection of tappet ............................... 13-171 connecting rod ..................................... 13-235
Standards for pitting when reusing.. .. ..13-17 3 Inspection of piston.. .............................. 13-236
Standard for deterioration (breakage) Inspection of piston pin ......................... 13-237
of tip ...................................................... 13-174 Inspection of connecting rod.. ............... 13-237
Inspection of camshaft bore ................. .13-177 Inspection of connecting
Replacement of camshaft bushing.. ....... .13-177 rod bearing clearance .......................... 13-237
Installation of tappet .............................. 13-178 Assembly of piston connecting rod.. ... .13-238
Installation of camshaft ......................... 13-181 Inspection of piston ring end gap.. ...... .13-239
Cleaning of camshaft ............................... 13-183 Installation of piston ring.. ..................... 13-240
Inspection of camshaft, gear ................ .13-184 Balancer ...................................................... 13-241
Replacement of camshaft, gear.. .............. .13-186 Disassembly ........................................... 13-241
Cleaning and inspection ........................ 13-187 Assembly ................................................ 13-244
Installation .............................................. 13-188 Gear housing .............................................. 13-251
Replacement of timing pin.. ....................... 13-190 Replacement of gear cover.. .................... 13-251
Replacement of gear housing, gasket ....... 13-191 Removal .................................................. 13-251
Removal .................................................. 13-191 Cleaning and inspection ........................ 13-252
Cleaning and inspection ........................ 13-192 Installation .............................................. 13-252
Installation .............................................. 13-193 Installation of gear cover ....................... 13-254
Repositioning of timing pin .................. .13-196 Inspection of gear housing
0’ Replacement of camshaft gear.. .............. 13-201 and timing pin ...................................... 13-256
% Removal .................................................. 13-201 Disassembly of gear housing ................ 13-256
6 Installation (shrink-fitting method) ...... .13-202 Replacement of fuel injection
Installation pump mounting stud ........................... 13-257
(method using special tool). ................ 13-203 Replacement of engine name plate ..... .13-257
Installation of camshaft Cylinder head .............................................. 13-260
mounting bolts ..................................... 13-205 Disassembly and assembly drawing ... 13-260
Replacement of vibration damper, Outline ....................................................... 13-262
crankshaft pulley ...................................... 13-206 Replacement of cylinder head ................. 13-263
Removal .................................................. 13-206 Removal .................................................. 13-263
Inspection of rubber damper.. ............... 13-206 Inspection before disassembly
Installation .............................................. 13-207 of cylinder head .................................... 13-266
Inspection of viscous damper ............... 13-207 Disassembly of cylinder head ............... 13-267
Vibration damper (rubber type). ........... .13-209 Cleaning of cylinder head ............. , ........ 13-268
Cleaning and inspection ....................... .13-209 Inspection of valve .................................. 13-270
Piston, pin, connecting rod ........................ 13-21 1 Inspection of valve guide.. ..................... 13-271
Replacement of piston and ring ........... .13-211 Inspection of cylinder deck.. .................. 13-271
Removal of piston connecting rod.. ..... .13-212 Inspection of valve seat ......................... 13-272
Disassembly of piston Standards for cracks in cylinder
connecting rod ..................................... 13-214 head when reusing.. ............................. 13-272
Cleaning of piston, pin, Replacement of valve spring ................. 13-273
connecting rod ..................................... 13-214 Assembly of cylinder head .................... 13-273
Inspection of piston.. .............................. 13-215 Adjusting valve clearance.. .................... 13-278
Inspection of piston pin ......................... 13-216 Installation of belt tentioner .................. 13-280
Assembly of piston connecting rod.. ... .13-217 Installation of alternator ........................ 13-280
Inspection of piston ring gap ............... .13-218 Installation of drive belt.. ....................... 13-281
Installation of piston ring.. ..................... 13-219 Inspection before disassembly ............. 13-281
Installation of piston connecting rod.. . 13-220 Disassembly of cylinder head ............... 13-282
Replacement of connecting rod ............. .13-224 Cleaning of cylinder head.. .................... 13-283
Removal .................................................. 13-224 Inspection of valve ................................. 13-285
Cleaning and inspection ........................ 13-225 Inspection of valve guide.. ..................... 13-286
13-3
0
Inspection of cylinder head Front support ............................................ 13-334
combustion deck .................................. 13-286 Cleaning and inspection ..................... 13-334
Inspection valve seat.. ............................ 13-287 Removal of engine ................................... 13-335
Standards for cracks Inspection of engine mount.. .................. 13-337
in cylinder head when reusing ........... .13-287 Installation of engine.. .............................. 13-338
Replacement of valve spring ................ .13-288 Oil pan and suction tube ......................... .13-342
Replacement of cap.. .............................. 13-288 Disassembly and assembly drawing . . 13-342
Polishing valve ....................................... 13-290 Replacement of oil pan,
Polishing valve seat ............................... 13-291 suction tube, gasket ............................... 13-343
Rocker lever ................................................ 13-298 Cleaning and inspection ..................... 13-345
Disassembly and assembly drawing ... 13-298 Regulator valve ......................................... 13-346
Outline.. ................................................... 13-300 Replacement of regulator valve,
Replacement of rocker lever spring ................................................. 13-346
and push rod ........................................ 13-301 Cleaning and inspection ..................... 13-346
Removal .................................................. 13-301 Oil filter bypass valve ............................... 13-349
Disassembly of rocker lever ................. .13-302 Replacement ......................................... 13-349
Cleaning of rocker lever.. ....................... 13-303 Oil cooler ................................................... 13-350
Inspection of rocker lever ...................... 13-303 Disassembly and assembly drawing . . 13-350
Assembly of rocker lever ...................... .13-304 Replacement of oil cooler core,
Installation of rocker lever ..................... 13-305 gasket .................................................. 13-351
Disassembly of rocker lever .................. 13-307 Cleaning ................................................ 13-353
Cleaning of rocker lever, Inspection ............................................. 13-354
rocker lever shaft.. ................................ 13-308 Oil pump ................................................... 13-355
Inspection of rocker lever ...................... 13-309 Disassembly and assembly drawing . . 13-355
Assembly of rocker lever ....................... 13-309 Replacement of oil pump ................... 13-356
Tappet and push rod .................................. 13-311 Cleaning and inspection ..................... 13-357
Disassembly and assembly drawing ... 13-311 Installation of oil pump.. ..................... .13-360
Outline.. ................................................... 13-312 Inspection ............................................. 13-361
Cleaning of push rod ................................ 13-313 Fuel injection pump group.. .................... 13-365
Inspection of push rod ........................... 13-313 Disassembly and assembly drawing .. .13-365
Installation of push rod.. ....................... .13-313 Fuel injection nozzle group.. ................... 13-366
Inspection of tappet ............................... 13-314 Disassembly ......................................... 13-367
Engine mount group .................................. 13-316 Cleaning and inspection ..................... 13-368
Outline of flywheel housing ................. .13-316 Assembly .............................................. 13-370
Outline of flywheel, ring gear.. ............. .13-316 Feed pump
Outline of front support.. ....................... 13-316 (cylinder block mount type) .................. 13-373
Flywheel, ring gear.. ................................... 13-317 Replacement of feed pump
Inspection of flywheel, ring gear.. ........ .13-317 (diaphragm type) ................................ 13-373
Replacement of flywheel, ring gear.. ... .13-317 Replacement, assembly
Flywheel housing ....................................... 13-319 of feed pump (piston type) ............... 13-373
Replacement of rear oil seal .................... 13-319 Replacement, assembly of feed pump
Removal .................................................. 13-319 (piston type) .......................................... 13-375
Cleaning and inspection ........................ 13-321 Cleaning ................................................ 13-376
Installation .............................................. 13-321 Assembly .............................................. 13-376
Replacement of flywheel housing.. ........ .13-324 Installation ................................. i.. ........ 13-377
Removal .................................................. 13-324 Replacement of fuel filter.. ....................... 13-380
Cleaning and inspection ........................ 13-325 Fuel piping ................................................ 13-382
Installation Replacement of high-pressure
(dry clutch specification). ..................... 13-326 fuel piping (Bosch VE, Lucas CAV). .... 13-382
Inspection of radial runout Replacement of fuel supply piping
of flywheel housing.. ............................ 13-327 (Bosch VE, Lucas CAV) ...................... 13-383
Inspection of face runout Cleaning and inspection
of flywheel housing.. ............................ 13-329 of high-pressure fuel piping ............. 13-385
Installation (wet clutch specification) . . 13-330 Replacement of fuel return piping
Inspection ............................................... 13-332 (Bosch VE, Lucas CAV) ...................... 13-386
Installation .............................................. 13-333 Cleaning and inspection
of fuel drain piping.. .......................... .13-388
13-4
0
Replacement of low-pressure
fuel piping (Bosch VE, Lucas CAV). .. 13-388
Cleaning and inspection
of low-pressure fuel piping .............. 13-389
Replacement of air-fuel
ratio control tube (Bosch VE) ........... 13-390
Water pump .............................................. 13-391
Disassembly and assembly drawing . . 13-391
Replacement of water pump .............. 13-392
Inspection ............................................. 13-393
Fan hub ..................................................... 13-393
Replacement of fan pulley.. ................ 13-393
Replacement of fan hub.. .................... 13-394
Inspection ............................................. 13-394
Disassembly ......................................... 13-395
Assembly .............................................. 13-396
Belt tensioner.. .......................................... 13-398
Replacement of belt ............................ .13-399
Replacement of belt tensioner ........... 13-399
Inspection ............................................. 13-399
Thermostat.. .............................................. 13-400
Replacement of thermostat.. .............. 13-401
Inspection ............................................. 13-402
Fan ............................................................. 13-404
Coolant ...................................................... 13-404
Component drive unit .............................. 13-406
Disassembly and assembly drawing.. .13-406
Cleaning ................................................ 13-407
Inspection ............................................. 13-407
Disassembly ......................................... 13-407
Assembly .............................................. 13-408
Disassembly unloader valve,
cylinder head ...................................... 13-410
Cleaning ................................................ 13-411
Inspection ............................................. 13-412
Assembly .............................................. 13-416
Replacement air compressor ............. 13-419
Removal ................................................ 13-419
Inspection ............................................. 13-420
Installation ............................................ 13-422
Alternator .................................................. 13-425
Inspection ............................................. 13-426
Starting motor .......................................... 13-426
Inspection ............................................. 13-427
13-5
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY
We recommend that you use the tools listed below. The tool to use is specified in the respective proce-
dure.
Tool No. Explanation of tool Sketch of tool
Fuel pump drive gear puller
795-799-1390
Compressor
795-799-l 120
Gear
795-799-l 130
Brush
795-799-l 140
Rebuilding stand
795-799-l 150
Adapter
.- .- -
52 cl
0
0
795-799-l 160 . -
.
.
.
.
3376975
13-6
0
Puller
795-799-l 170
Dial indicator
Commercially When measuring the radial runout of the fly-

available wheel and flywheel housing, use this together
with Part No. ST-1325 dial gauge attachment.
Ridge reamer
795-799-l 180
Tool kit
795-799-l 190
Installer
795-799-1370 This is used to install the lubricating oil

seal wear sleeve to the crankshaft.
3824078
Installer
795-799-1380 This is used to install the lubricating oil seal

wear sleeve for the crankshaft to the front cover
to the specified depth.
3824498
795-799-1460
795-799-1480
13-7
0
SPECIAL TOOLS FOR ENGINE
dure.
Driver
795-799-1230
795-799-1220
Splitter (use on engines before 1991)
795-799-1240
3823585
Installer
795-799-1340
Piston ring tool
795-100-2800
3823137
13-8
0
Brush
795-799-l 140
Depth gauge
795-790-1300
3823495
13-9
0
SPECIAL TOOLS FOR FUEL SYSTEM
dure.
Tool No. Exdanation of tool Sketch of tool
Tool puller
This is used to pull the front drive shaft seal

from the Bosch VE fuel pump.
795-799-1250
Sleeve
This is used to pull the front drive shaft seal
795-799-1260
from the Bosch VE fuel pump.
liming tool
3
0
038
13’”
3376936
This is used to check the static timing on the

Bosch VE fuel pump.
795-799-1270
Sleeve
This is used when replacing the O-ring for the

shut-off solenoid of the Lucas CAV fuel pump.
795-799-1280
Sleeve
This is used when replacing the O-ring at the

pressure end cap in the timing propulsion angle
0%’
795-799-1290
$6
Q
mechanism for the Lucas CAV fuel pump.
@
3376931
13-10
0
Nozzle tester
799-203-7700
3376946
Cleaning kit
795-799-1310
3376946
Puller
795-799-l 170
3376947
13-11
0
DISASSEMBLY AND ASSEMBLY OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE

OUTLINE
The procedure explained below is for the 102 series engine. The explanation also mentions differences
in the engine model because of the purpose, optional equipment for the engine, and the year of assem-
bly of the engine. Omit any procedure that is not related to your engine.
g Warning: A Warning is clearly given for any component or assembly if its weight exceeds 23 kg.
When installing or removing, use a hoist or ask for assistance, and take care to prevent injury.
A Caution: The fasteners are given in the metric system. Basically, all fasteners have right-hand
threads. If any fastener has a left-hand thread, it is cleared indicated.
Disassembly
The explanation of the procedure for disassembly of the engine is given in the logical order. This is not
simply the order for disassembling the engine. Depending on the part, it may be necessary to remove it
in the order explained. Always follow this order until you fully understand the engine.
Dispose of all gaskets, seals, hoses, filters, and O-rings. If they are necessary for analysis of any failure,
keep these parts in a safe place. When removing the parts, fix labels, tags, or make marks to show the
position of the part. This helps in identifying parts related to any failure, and also makes the assembly
procedure easier.
Before removing any special components from the engine, fix labels or tags, or make marks, or take
photographs. The installation of special optional component is not included in the assembly procedure.
When applying force to remove any part, use a mallet. When using a mallet, always remove the fasten-
ers first.
Be careful not to let dirt get on the parts during assembly. If dirt accumulates, it is difficult to clean the
components.
Assembly
The assembly procedure assumes that all components and assemblies have been cleaned, replaced, and
reassembled, and that preparations have been made to install them to the engine.
The torque values for each procedure are given.
Many gaskets and O-rings are made from material designed to absorb oil. If the gaskets or O-rings
come into contact with oil, they expand and the sealing effect is increased. When installing these parts,
use only the recommended adhesive or vegetable oil.
13-12
0
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF ENGINE
DISASSEMBLY OF ENGINE
STEAM CLEANING OF ENGINE
tive clothing,
shield.
safety glasses, and face
Hot steam may cause serious
A
burns.
Caution: Fit covers to the openings of the engine

and to the electrical components, and be
careful not to get water on these parts.
q
Use steam to clean off any excessive dirt on the
outside of the engine. \ ew900ed
REMOVAL OF STARTING MOTOR

10 mm
Remove the starting motor.
Es
z st900mc
6
WEIGHT OF ENGINE (REFERENCE
VALUE NOT INCLUDING AUXILIA-
RIES SUCH AS MUFFLER)
3822512 Engine lifting equipment
r+ kg 4D102 engine (wet): 325 - 350 kg
&I kg 6D102 engine (wet): 410 - 440 kg
I em9OOhf
INSTALLATION TO ENGINE STAND

18 mm, engine rebuilding stand, adapter (795-
799-l 160)
w :
Install the engine to the rebuilding
77 NmI7.9 kg}
stand.
0%
Installation hardware: Ml2 x 1.75
em9OOke
13-13
0
DRAINING OIL
22 mm
Remove the drain plug.

El
A drain pan with a 30 liter capacity is sufficient. 6%
Q
op9psma
REMOVAL OF REAR LIFTING

BRACKET
18 mm
Remove
head.
the rear lifting bracket from the cylinder
63
Q
la9bkma
REMOVAL OF BELT
If excessive force is applied to the tensioner in the
opposite direction from winding in or when the
tensioner has been wound in to the normal stop
position, there is danger that the tensioner arm may
break.
Caution: Do not put your hand near the path of

the tensioner when it is under the force *i
of the spring.
Loosen the tension with a l/2 inch or 3/8 inch square

headed wrench, then remove the drive belt.
Operating hint: Remove the drive belt after loos-

ening the vibration damper crankshaft and hub
pulley mounting bolt.
fa9blma
13-14
0
REMOVAL OF FAN PULLEY

14 mm
Remove the fan pulley and mounting bolt.
fa9puoa
REMOVAL OF VIBRATION
DAMPER, CRANKSHAFT PULLEY
15 mm
Remove the vibration damper or crankshaft pulley %Q

and mounting bolts.
e
da9puma
I
REMOVAL OF BELT TENSIONER

15 mm
Remove the belt tensioner from the bracket.

El
%Q
q@
5 mm hexagon wrench
Remove the tensioner bracket. RI

%Q
REMOVAL OF FAN HUB

IOmm
Remove the fan hub.
Caution: For details of the procedure for inspec-

tion of the fan hub, see Component.
REMOVAL OF ALTERNATOR
13 mm
Remove the alternator link.
16mm
Remove the alternator mounting mounting bolt

and alternator.
13 mm
Remove the alternator bracket.
13-16
0
REMOVAL OF THERMOSTAT
IO mm
Remove the mounting bolts from the thermostat

housing.
Remove the thermostat housing, gasket, thermo-

stat and lifting bracket.
Caution: For details of the procedure for inspec- @

tion of the thermostat, see Component.
th9hsma
Screwdriver
If aftercooler supply tube (I) and coolant return

tube (2) are installed, remove them.
REMOVAL OF TURBOCHARGER
(ENGINE WITH TURBOCHARGER)
16 mm and 19 mm
Remove the oil supply line from the turbocharger

and oil filter head.
10 mm, Screwdriver
Remove the air crossover tube.
On the automobile engine, loosen the V-band

clamp and hose clamp, then remove the intake tube
of the charge air cooler.
10 mm
Remove the drain tube connection from the bot-
tom of the turbocharger.
tblcsma
Remove the turbocharger drain line from the cyl-

inder block drain tube.
13-18
0
On engines with a westgate turbocharger, remove

the westgate intake hose.
15 mm
Remove the turbocharger mounting nuts, turbo-

charger, and gasket.

tion of the turbocharger, see Component.
REMOVAL OF EXHAUST MANI-

FOLD
13 mm
Remove the mounting bolts, exhaust manifold, and

casket.
Caution: For details of the procedure for inspec- @

tion of the exhaust manifold, see Com-
ponent.
xm9s kma
REMOVAL OF FUEL FILTER

75-80 mm, 90-95 mm strap wrenches
Remove the fuel filter.

REMOVAL OF FUEL FILTER HEAD

24 mm
If a dual filter head is installed, remove the nut,

dual filter head, and O-ring. AY_
Screwdriver
Remove fuel filter adapter and o-ring.

rn.
%Q
REMOVAL OF FUEL PIPING

Removal of high-pressure fuel piping
14 mm, 17 mm crowsfoot
crosfoot wrench
wrench, 19 mm
El
Caution: When loosening the high-pressure line of
the rotary pump, support the fuel pump A
discharge valve securely.
Remove the high-pressure

injection pump.
line fitting from the fuel
%Q
17 mm, 19 mm
Remove the high-pressure line from the injector.
Caution: For details of the inspection of the fuel

line, see Component.
13-20
0
10 mm
Remove the mounting bolts from the manifold

cover securing the high-pressure line support
bracket.
Remove the high-pressure line as an assembly.
install a cap or cover to the injector opening.
17 mm and screwdriver
If an air-fuel control tube is installed, remove the

air-fuel control tube and turbocharger
line.
westgate
c%
Q
Removal of fuel spill piping

10 mm
Remove the seal washer and joint bolt of the fuel

spill tube from the injector.
13-21
0
17 mm and IO mm
Remove the support bracket from the fuel spill tube.
Removal of low-pressure fuel piping

17 mm, 12 mm
Remove the seal washer and joint bolt of the fuel

injection pump and filter head.
Remove the mounting bolts of the fuel tube sup-

port bracket from the intake manifold.
--- ft9tbme
REMOVAL OF DIPSTICK
17 mm
If a dipstick tube extension is installed, remove the

dipstick tube extension.
REMOVAL OF INTAKE MANIFOLD

COVER
10 mm
If they are installed, remove the manifold cover,

gasket, and grid heater.
im9cvml
13-22
0
REMOVAL OF AFTERCOOLER
(ENGINE WITH AFTERCOOLER) kl
IO mm
Q
8
If an aftercooler is installed, remove the housing.
G@
REMOVAL OF CYLINDER HEAD

COVER
15 mm
Ia
Remove the special mounting
cover, and gasket.
bolts, O-ring, valve %0
REMOVAL OF FUEL INJECTION

NOZZLE
RI
Rust penetrant
Caution: If there is rust on the mounting nut, the
injector will rotate in the bore when the
%Q
nut is loosened. If this happens, the in-
jector locating ball will cut a groove on
0o?
the inside surface of the bore and dam-
age the head.
Apply rust penetrant to the mounting nut and soak f i9OOwd
for at least 3 minutes.
Brass drive pin, hammer
Caution: lf the force is too strong, the injector will A

be damaged.
Hit the injector with a hammer and drive pin and

remove the rust.
f i900we
13-23
0
24 mm box wrench, universal wrench
Hold the injector with a universal wrench and

loosen the mounting nut with a 24 mm box wrench.
Puller (795-799-1170)
Remove the injector.

If it is difficult to remove, remove the injector O-
lsl
ring and apply penetrant to the bore around the
injector. Install an injector puller and pull the in-
jector out as far as possible. Hit with the injector
CR
Q
puller slide hammer in the direction of the puller
nut to push the injector into the bore. By repeat-
ing this procedure, the penetrant penetrates the in-
jector tip and softens the carbon deposited at the
tip.
Caution: For details of the testing procedure for fi900vc

the injector, see Component.
REMOVAL OF ROCKER LEVER

14 mm, screwdriver
Loosen the rocker lever adjustment screw until it

stops.
l---
rh9asma
13 mm, 18 mm
Remove the holder/head bolt from the rocker shaft

holder, then lift up the holder and rocker lever as-
sembly.
Caution: For details of the disassembly of the rocker

lever assembly, see Component.
13-24
0
REMOVAL OF PUSH ROD

Remove the push rods.

tion of the push rods, see Component.
REMOVAL OF CYLINDER HEAD

18 mm
Remove the cylinder head mounting bolts in the

order shown in the diagram.
- - - -
knScsma
Remove the head and gasket from the block.

Q
GS
Weight of cylinder head:
k 4-cylinder engine - 36 kg
@
$ ks 6-cylinder engine - 52 kg
@
Caution: For details of the procedure for disassem-
bly of the head, see Component.
REMOVAL OF FRONT COVER

90-100 mm strap wrench
Remove the front cover access cap.
Operating hint:
When loosening the access cap after it has been
tightened too much, use a strap-type filter
wrench.
ac9camb
13-25
0
IOmm
Remove the front cover and gasket.
oc900me
Hammer, punch
Support the front cover seal portion, and peel off

the seal.
!mb
REMOVAL OF WATER PUMP

13 mm
Remove the water pump and O-ring.

tion of the water pump, see Component.
REMOVAL OF FLYWHEEL
18 mm
Lock the crankshaft, then remove the mounting

bolts, washers, and flywheel.

tion of the flywheel, see Component.
J0’ fh90 )ml
13-26
0
REMOVAL OF FLYWHEEL HOUS-

ING
15 mm
Remove the flywheel housing.

tion of the flywheel housing, see Com-
ponent.
REMOVAL OF COMPONENTS I
(COMPRESSOR, HYDRAULIC
PUMP, ETC.)
IO mm, 14 mm, 18 mm
Q
Qx
If gear drive accessories (air compressor, hydrau-
lic pump, etc.) are installed, remove them. @
Caution: When carrying out repairs, follow the in-

F
5:
CI)
6
REMOVAL OF FUEL INJECTION

PUMP (BOSCH A, ZEXEL A)
Caution: Be careful not to let water or dirt get into
the fuel system of the diesel engine. Even
small amounts of dust or just 2 or 3 drops
of water in the fuel system will cause
damage to the system.
Clean the external surface of the fuel injection

pump, including the line connections and fittings
that are to be disconnected. Clean the area around
the fuel injection pump gear cover, and be careful
not to let dirt get into the crankshaft case.
Preparations before starting:
l Remove the fuel line.

l Remove the control link mechanism.
l Remove the linkage mounting nuts from the
stop solenoid.
l Remove the fuel filter.
13-27
0
10 mm
Remove the mounting bolts, oil cooler cover, cover

gasket, oil cooler, and cooler gasket.
Caution: For details of the procedure for inspec- Q

6x
tion, see Component.
@
I c9cvma
REMOVAL OF WATER INLET

13 mm
RI
Remove the coolant inlet portconnection and rect-
angular ring seal. Q
6x
REMOVAL OF OIL PAN

IO mm
Rotate the engine on the stand and remove the oil

pan.
REMOVAL OF OIL PAN SUCTION

TUBE
10 mm
q
Remove the suction tube and gasket. Q
62
REMOVAL OF REAR SEAL COVER

8mm
RI
Remove the rear seal housing and gasket.
Q
C%
Support the seal portion of the rear seal housing,

and press the seal out.
ks9semf
REMOVAL OF CAMSHAFT
Measuring backlash of gear
Set the indicator in contact with the tooth of the
camshaft gear.
Caution: The position of the cylinder block is shown

in the diagram to make it easy to under-
stand. The upper crankshaft must be used
to position the cylinder block so that the
tappet is kept inside the bore.
CQgQeis
Note down the backlash of the camshaft gear. If
the backlash exceeds the limit, make marks on the
camshaft gear and crankshaft gear as preparation
for later analysis.
Limit (A) for backlash of camshaft gear

mm
0.076 MIN
0.330 MAX
Note: When inspecting the backlash, stop the

movement of the neighboring gears. If this
is not done, the reading will be the total for
both gears. CQgQrCa
13-32
0
Rotate the crankshaft to set the No. 1 cylinder to

the TDC position. If this is not done, the camshaft
will catch on the connecting rod when the cam-
shaft is removed.
Caution: The position of the cylinder block is shown

in the upright position in the diagram to
make it easy to understand.
13 mm
Remove the mounting bolts from the thrust plate.
0a5
Inspect the tappet visually to check that it is sepa-
rated from the camshaft lobe.
n kf9OOca
Remove the camshaft and thrust plate from the

cylinder block. Be careful not to drop the thrust
washer.
Operating hint:
When removing the camshaft, rotate it and pull
it with a fixed force to the outside.

tion and disassembly, see Component.
REMOVAL OF TAPPET
Remove the valve tappet. If the engine is rotated,
it is easy to get close to the tappet.

tion, see Component.
A I 1 kf9OOme
REMOVAL OF OIL PUMP

lubricating pump gear.
Note down the backlash of the lubrication pump

gear.
If the backlash exceeds the limit, make marks on
the pump gear and idler gear as preparation for
later analysis.
Limit (A) for backlash of lubrication

pump gear.
mm
0.076 MIN
0.330 MAX
I ID9eeib

both gears.

idler gear.
ID9eeic
13-34
0
Note down the backlash of the idler gear.

If the backlash exceeds the limit, make marks on
the idler gear and crankshaft gear as preparation
for later analysis.
Limit (A) for backlash of lubrication

pump idler gear.
mm
0.076 MIN
0.330 MAX
IPSaeid
NOTE: When inspecting the backlash, stop the
movement of the neighboring gears. If this is not
done, the reading will be the total for both gears.
13 mm
Remove the lubricating pump.
REMOVAL OF TIMING PIN HOUS-

ING
T25 Torx
Remove the timing pin assembly.
REMOVAL OF GEAR HOUSING

10 mm
Remove the mounting bolts, gear housing, and

gasket.
Plastic hammer
The gear housing is positioned on the cylinder

block with two dowel pins. If it is difficult to re-
move the housing, hit the dowel pin portion with a
plastic hammer.
REMOVAL OF BALANCER
(WHEN BALANCER IS INSTALLED)
Using an indicator, measure the backlash of idler
gear (A), upper shaft gear (B), and lower shaft gear
(0.
both gears.Plastic hammer
Backlash of balancer gear

mm
Idler (A) to (D) 0.088 MIN
0.420 MAX
Upper (B) to (A) 0.153 MIN
shaft 0.355 MAX
Lower (C) to (B) 0.088 MIN
shaft 0.420 MAX
Record for use during inspection.
Measuring end play
Use the indicator to measure the end play of idler

gear (D) and shaft(E).
End play of balancer tags.5 i I

mm
0) 0.130 MIN
0.630 MAX
(0 0.075 MIN
0.175 MAX
Record for use during inspection. For details of

the procedure for disassembly and assembly, see
Component.
Fixing balancer
Rotate the balancer gear until the timing marks are

0a
ba9seca
aligned.
13-36
0
._. . . . _
It there IS a tapped hole In the balancer shaft, it is
possible to temporarily fix the shaft through the
housing with an M8 mounting bolt to lock the shaft
in the fixed position.
4.5 mm, 1 inch wide masking tape
If there is no tapped hole in the shaft, do as fol-

lows.
Wrap masking tape around a 4.5 mm hexagon
wrench so that it matches the hole in the balancer
housing exactly.
A = Approx. 10 mm
B=lOmm
tpiha
Removal of balancer
8 mm hexagon wrench
Loosen the mounting bolts of the balancer idler

gear retainer and socket head. Do not remove the
mounting bolts.
wa
Remove the mounting bolts of the No. 1 and No. 4

main bearings.
Move the idler retainer to a position where the No.

1 cap pin comes out from the retainer slot. Re-
move the balancer assembly.
REMOVAL OF PISTON CONNECk

ING ROD
Make match marks on each connecting rod cap to
match the cylinder.
032
Rotate the engine on the rebuilding stand to bring
the cylinder bore to the side.
Rotate the crankshaft and set so that the piston is
under the carbon deposit at the top of the ring
stroke.
cklbr 1:
q
Use a scraper or tool without a sharp point to re- \
move the carbon deposit. Be careful not to scratch
the cylinder with the scraper.
I,0 - C\Ek9brxj
13-38
0
q
If any carbon cannot be removed, use a Scotch- \
Brite@ cleaning pad or equivalent to remove the
carbon.
A
Warning: Wear protective glasses during this op-
eration and be careful to prevent injury
to your eyes.
q
Another way to remove the carbon is to use a drill
with a high-quality steel wire wheel or die grinder. \
Caution: If a low-quality wire wheel is used, the

steel wire will come out during the op-
eration and make the dirt worse.
Do not use a steel wire wheel for the piston stroke.

When removing the deposit with the wheel, move
the wheel in a circle.
Ridge reamer
If necessary, remove the ridge from the top of the
cylinder. Be careful not to let the ridge reamer cut
into the cylinder bore, and be careful not to grind
off too much metal.
Mark the cylinder number on each piston.
V0
> c3
The piston must be installed to the correct cylin-
0
0
der number during assembly.
0
0
3
0
&
DiSOOsc
13-39
0
Remove the main bearing cap.

Do not use a lever to remove the main cap from
the cylinder block. Hold the two bolts of the main
c%
Q
cap and loosen the main cap by moving in small
movements backward and forward. When doing
this, be careful not to damage the threads of the
bolt.
Weight of crankshaft:
k 4-cylinder engine - 36 kg
@Ikg 6-cylinder engine - 55 kg
Lift up the crankshaft and gear from the cylinder

block.

tion and disassembly, see Component.
3/16 inch pin punch
Remove the piston cooling nozzle.

Install the main cap to the matching piston.

If the main cap is installed properly, the tag (slot)
will be on the same side.
Caution: The No. 1 cylinder is at the front of the

block.
mb900la
REMOVAL OF TURBOCHARGER
LUBRICATION DRAIN TUBE
3/4 inch drift and hammer
RI
Push the drain tube out from the inside the cylin-
der block.
6%
Q
ck9tbmb
REMOVAL OF CYLINDER BLOCK

FROM ENGINE STAND
18 mm
Remove the cylinder block from the roll-over stand.

tion and cleaning of the cylinder block,
see Component.
Weight of 4B cylinder block: 91 kg

Weight of 6B cylinder block: 124 kg
ck900wk
13-42
0
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF ENGINE
ASSEMBLY OF ENGINE
PREPARATION FOR ASSEMBLY OF
CYLINDER BLOCK
Install the cylinder block to the roll-over stand. Q
62
Caution: Check that the cylinder block has been ,.$@,

cleaned and inspected.
ck900wk
Caution: Check that the cylinder bore is clean.

A
INSTALLATION OF TAPPET
Coat the tappet with lubricating oil.
kf900we
Install the valve tappet.

Assemble the 2nd journal from the rear, then in-

stall the thrust and main bearing.
Coat the bearing with Lubriplate 105@.

%
Ll
Caution: Install to the crankshaft carefully and be

careful not to damage the crankshaft and main
bearing, and in particular the thrust and main bear-
ing.
Install the crankshaft.
Weight of crankshaft :
4 Cylinder - 36 Kg
6 Cylinder - 55 Kg
ks900ha
Check that the ring dowel is installed to the cap.
mb9doha
Install the lower main bearing to the cap.

Coat the bearing with lubricating oil.
Check that the bearing tongue is installed inside
the notch in the bearing cap.
mb9bena
There are numbers on the main bearing caps. No.

1 starts from the front of the block. Install with the
number facing the engine oil cooler side.
mb9OOah
Set the main bearing and cap in position.
Coat the bottom of the head and the mounting bolts

of the main bearing with clean oil.
:hd
13-46
0
The end play is determined by the dimensions of

the thrust bearing and crankshaft journal.
Measure the end play.
Limit (A) for end play

mm
0.102 MIN
0.432 MAX
ks90lna
INSTALLATION OF PISTON AND

CONNECTING ROD ASSEMBLIES.
Rotate the engine stand and set the crankshaft per-
pendicular.
Caution: If the engine is rotated more than 90”, the

tappet will fall out.
INSTALLATION OF PISTON AND

CONNECTING ROD ASSEMBLY
Install the bearing shell to the connecting rod and
cap.
Check that the bearing shell tongue is fitted inside
the cap and connecting rod slot.
cx9behd
Coat the connecting rod bearing thinly with lubri-

cating oil.
13-48
0
Coat the ring and piston skirt with clean oil.

q
e,
Set the rings in position.
Caution: For details of the procedure for installing

the ring to the piston, see Component.
pi9rihb
75 - 125 mm I3 - 5 in1 ring compressor
Caution: When using a strap type ring compres- RI

sor, be careful that the tip of the strap on
the inside does not catch in the ring gap A
and damage the ring.
Compress the ring with the compressor.
Pi9tohb
Coat the cylinder bore with clean oil.

Set the connecting rod journal of the piston to be

installed to the bottom dead center (BDC) position.
Caution: When inserting the connecting rod, be

careful not to damage the wall of the cyl-
A
inder.
@3
Set the FRONT mark on the piston facing the front @
0
of the cylinder block, and install the piston and
connecting rod assembly in the cylinder bore. @
PiSOOhb
Guide the connecting rod to the crankshaft journal

and push the piston carefully into the bore.
Coat the bottom of the head and thread of the con-

netting rod mounting bolts with oil.
1-L-I cx9cswb
13-50
0
INSTALLATION OF GEAR HOUS-

ING
Mallet
If they have been removed, install the 2 gear hous-
ing dowel pins.
Fit the tapered end of the dowel exactly in the cyl-

inder block.
Install the pin in the bottom of the hole.
ck9dohb
Install the gear housing gasket.
PhSakhb
10 mm
Install the gear housing and mounting bolts.

Coat the mounting bolts with lubricating oil.
w: 24 Nm I2.4 kgm)
shahsha
Caution: Check that the correct pump is installed. A

The .pump for the 4-cylinder engine and
the pump for the 6-cylinder engine are
not interchangeable.
A = Dimension of 4-cylinder engine,

trochoid gear: 12.947 mm
B = Dimension of 6-cylinder engine

trochoid gear: 17.947 mm
13-52
0
INSTALLATION OF OIL PUMP

Coat the pump with clean oil.
5
Caution: To assist the priming when starting the 0
A
engine, fill the lubricating oil pump with
oil before installing.
Fit the idler gear pin exactly in the bore for posi-
tioning the cylinder block.
Install the lubricating oil pump.
Ip900hf
When installing the oil pump to the cylinder block,

there should be a clearance between the pump
flange and cylinder block. Do not tighten the
mounting bolts excessively to close the gap. If the
mounting bolts are tightened excessively, the oil
pump will be damaged.
Ip900wd
13 mm
Tighten the mounting bolts in the order shown in

the diagram.
m: 24 Nm I2.4 kgm}
Caution: When installing a new pump, check that

the backlash of the gears is correct.
Use a dial indicatorto measure the backlash of the

gear.
Measure the backlash of the gear.

r%I
w
Limit for backlash
A B
0.08 to 0.33 mm 0.08 to 0.33 mm

both gears.
edc
INSTALLATION OF CAMSHAFT
Rotate the crankshaft and set the No. 1 cylinder to
the TDC position. TD
If the position is correct, the gear alignment pin of
the crankshaft will be at the 12 o’clock position.
Caution: If the position is not correct, the camshaft

12 O’c
may contact the connecting rod during in-
stallation.
Coat the camshaft bore with Lubriplate.
13-54
0
Coat the camshaft journal lobe with lubricating oil.
cs900ra
Push the camshaft and cam gear assembly into the

cylinder block to the final journal.
Install the camshaft. Push the camshaft in lightly
and rotate it carefully to pass it through the cam-
shaft bushing. When the camshaft journal passes
through each bushing, the camshaft will go down
slightly, so the camshaft lobe will catch on the
bushing. If the camshaft is rotated, the lobe is re-
leased from the bushing and it is possible to in-
stall the camshaft.
Before meshing the camshaft gear with the crank-

shaft gear, check the camshaft so that it can rotate A
easily. If it is installed correctly, the camshaft will
rotate freely.
Coat the thrust plate with lubricating oil.

Align the timing mark as shown in the diagram,
and install the thrust washer.
cs9seda
13 mm
Push the camshaft into the cylinder block. Install

the thrust plate mounting bolts.
m: 24 Nm I2.4 kgm}
Measure the end play of the camshaft.

The end play is controlled by the thickness of the
thrust plate and the groove in the camshaft.
MEASURING CAMSHAFT END PLAY
Limit (A) for camshaft end play

mm
0.12 MIN
0.34 MAX
ca9aeje
Caution: If the gear has been replaced,

the backlash is correct.
check that
A
Using an indicator, measure the backlash.
13-56
0
MEASURING CAMSHAFT GEAR BACK-

LASH
Limit (A) for camshaft backlash

mm
0.076 MIN
0.380 MAX
cslaejd
INSTALLATION OF TIMING PIN
Caution: The timing pin assembly is precisely lo-

cated on the gear housing to correspond
to TDC for Cylinder No.1.
A
Caution: If the gear housing is interchanged, the
timing pin assembly must be relocated.
10 mm, 15 mm
Rotate the cylinder block on the rebuilding stand

until the combustion deck is positioned at the top
and it is parallel to the floor.
When setting the position of the assembly again,
install the crankshaft pulley and assembly wire
pointer temporarily. To prevent damage to the gear
housing, use a plain washer between the pointer
and the gear housing.
Assemble the steel plate as shown in the diagram.

2 drill holes
itStoxi
13-57
0
15 mm
Using two flywheel housing mounting bolts, install El-

the steel plate on top of the No. 1 cylinder.
Rotate the crankshaft until the piston contacts the

steel plate. Make marks on the pulley.
Rotate the engine in the opposite direction until

the piston contacts the steel plate. Make marks on
the pulley.
Make the TDC mark on the pulley.

The TDC position is half the distance between the
first two marks.
13-58
0
15 mm
Remove the steel plate, then rotate the engine un-
til the pointer is aligned with the TDC mark.
Inspect the timing pin hole in the camshaft gear. If

it cannot be seen, rotate the crankshaft one more
turn.
Align the pointer with the TDC mark.
i t900we
T-25 Torx
Install the timing pin assembly.
I i t9Piml
Push the pin into the cam gear hole, and center
the housing.
Leave the pin inserted and tighten the torque screw.
m: 5 Nm IO.51 kgm}
hd
13 mm
If there is a tapped hole in the balancer shaft, M8

mounting bolts can be passed through the hous-
ing and tightened temporarily to the shaft to lock
the shaft in the fixed position.
4.5 mm, 1 inch wide masking tape
Caution: Check if the mounting bolts of the idler

gear retainer are loose.
If there is no tapped hole in the shaft, do as fol-

lows.
Wrap masking tape around a 4.5 mm hexagon
wrench so that it fits the hole in the balancer hous-
ing exactly.
A = Approx. 10 mm
B=lOmm &-e ba9Pi ha
Install the main bearing cap to the lock type bal-

ancer assembly.
Position the assembly securely with the alignment
lug facing the cap.
ha
Align the center of the positioning pin of the main

gear cap and the idler gear retainer slot. Slide the
balancer to the set position.
Rotate the idler gear slightly to make alignment

easier.
Coat the thread of the main bearing mounting bolt

and the bottom of the head of the mounting bolt
with clean oil.
0
If the mounting bolts cannot be installed, check that a
the engine piston is at TDC.
ba9OOva
23 mm
Tighten the mounting bolts uniformly in the order

shown in the diagram.
Step Tightening torque value
1 60 Nm (6.1 kgm}
2 119 Nm (12.1 kgm}
3 176 Nm U7.9 kgm}
13-62
0
Remove the stopper bolt or hexagon wrench from

the balancer.
8 mm hexagon wrench
Installation of idler gear retainer

Tghten the bolts.
w: 57 Nm I5.8 kgm}
Note down the backlash of the idler gear.
Limit of backlash
mm
0.088 MIN
0.420 MAX
If the idler gear does not match the specifications,

loosen the mounting bolts of the idler gear retainer.
0K
Position the idler gear again, then tighten the
mounting bolts.
m: 57 Nm I5.8 kgm)
032
The crankshaft must be able to rotate freely.
If the crankshaft does not rotate freely, check if the

balancer is causing interference.
13-63
0
MEASURING END PLAY OF CRANK-

SHAFT
Put a dial indicator in position and measure the
end play of the crankshaft.
Limit for end play of crankshaft

mm
0.102 MIN
0.432 MAX
ks900j b
INSTALLATION OF REAR OIL SEAL

Inspect the crankshaft flange and rear cover to
check that there is no dirt or damage. Use a clean-
ing pad (part number 795-799-1460) to remove the
dirt and rust. Wipe the crankshaft flange and dry
it.
ks900eh
Install the rear cover and gasket. When doing this, 4~ -

tighten the mounting bolts partially. Do not tighten @
@
them to the specified torque.
There is a pilot tool installed to the replacement

rear seal. Do not remove the pilot tool at this point.
I ks9sesa
13-64
0
Coat the rubber outside diameter of the oil seal with

non-irritant soap.
ks9sewa
Use the alignment installation tool in the seal kit.

Push the seal into the housing to the bottom of the
driver.
Caution: Instead of this, it is possible to set the seals

to the 12 o’clock, 3 o’clock, 6 o’clock, and
9 o’clock positions, and to install a square
seal to the crankshaft flange.
Check that the seal housing is flat with both ends

of the oil pan rail on the cylinder block. Tighten
the rear cover mounting bolts.
w: 7 Nm (0.71 kgm}
Remove the seal pilot tool.

Trim the gasket so that it matches the oil pan mount
surface.
INSTALLATION OF OIL PAN SUC-

TION TUBE
Set the suction tube and gasket to the cylinder
block.
ck9tbha
13-65
0
10 mm, 13 mm
Tighten the mounting bolts of the oil suction tube
m:
and brace.
24 Nm 12.4 kgml
INSTALLATION OF OIL PAN

Oil pan seal surface - sealant
Fill the space between the oil pan rail, gear hous-
ing, and rear cover with LG-7.
Coat the cylinder block end of the head plate and

oil pan flange with LG-7. Be particularly careful
not to forget to coat the area around the suction
tube mounting hole (the arrow marks in the dia-
gram on the right).
10 mm
RI
Assemble the oil Dan and mounting bolts as shown
in the diagram.
w: 24 Nm 12.4 kgm}
13-66
0
IO mm
w: 24 Nm I2.4 kgm}
INSTALLATION OF FUEL INJEC-

TION PUMP (BOSCH A, ZEXEL A) @
Install the fuel injection pump O-ring. Check that
the position of the O-ring is correct and that it is
not damaged.
Es
4
._
iD9skha
6
Carry out barring of the engine, push the engine

timing pin in until it meshes, and set the No. 1 cyl-
inder to the top dead center (TDC) position.
In the fuel injection pump, timing pin (I), which

determines the position of the pump shaft at No. 1
cylinder TDC, is inside the governor housing. After
installing the pump, reverse the pin and store it in
housing (2).
24 mm
Remove the access plug.
Remove the timing pin.
If the timing teeth are not aligned with the timing

pin hole, rotate the shaft of the fuel injection pump
and align the timing teeth.
Reverse the position of the timing pin and align it

with the timing pin slot at the top of the timing
teeth inside the pump.
Using the access plug, install the timing pin and
fix it in position.
13-70
0
Pour clean engine oil into the gear cover housing

to make it easier for the fuel injection pump to slide
into the gear cover housing.
Add oil to the mounting flange of the fuel injection

pump.
Caution: Before installing the gear, clean the in-
side diameter of the fuel injection pump
drive gear and the outside diameter of
the shaft, and dry them.
Slide the pump shaft into the drive gear. Install

the pump flange on top of the mounting stud.
Push the pump forward until the mounting flange
and O-ring are aligned correctly with the bore of
the gear housing.
Do not try to pull the pump flange into the gear

housing with the mounting nut. There is danger
that it may damage the housing.
On the Bosch A and Zexel A, there is a timing pin

under the cap on the outside of the governor. When
unlocking the pump, reverse the position of the pin
under the cap.
Remove the meshing of the timing pin.
22 mm
Tighten the drive gear mounting nut.
Tightening torque value

0<
Bosch A, Zexel 95 Nm (9.7 kgm}
i P9seoa
Check that the backlash of the replaced gear is cor-

rect.
Measure the backlash with a dial indicator.

Limit for pump gear backlash

A = 0.076 - 0.330 mm
iD9sejb
IOmm
Install the fuel injection pump support bracket.
Tighten the mounting bolts by hand before tight-
ening to the final torque.
w: 43 Nm I4.4 kgm}
INSTALLATION OF COMPONENTS
(COMPRESSOR, HYDRAULIC
PUMP, ETC.)
If necessary, install the cover plate or other gear
drive accessories (hydraulic pump, air compressor,
etc.)
Caution: When installing gear drive accessories,

check that the correct support bracket has
been installed.
INSTALLATION OF FLYWHEEL
OB
HOUSING
@@ ouo 0 0
$01
If they were removed, install two ring dowels.
Push in the dowel until it contacts the bottom of 000
d3
the bore.
0
O
0O
0 0
\ 0
0 0
0of-J
--
A0 O/
_.
00
ckldohc
13-74
0
Install the rectangular seal, then coat with lubricat-

ing oil.
15 mm
Install the flywheel housing.
w: 77 Nm 17.9 kgml
h900ht
Install the flywheel.
Caution: Install 2 mounting bolts to the front of

the crankshaft, or lock the crankshaft and
tighten the flywheel mounting bolts. Do
not lock the engine with the timing pin.
f n900ha
18 mm
Tighten the mounting bolts in the order shown in w

0%
the diagram.
m: 137 Nm I14.0 kgml
f h9OOna
INSTALLATION OF WATER PUMP

Instal,l the O-ring in the water pump housing
groove.
nP9orht
13 mm
Install the water pump.
w: 24 Nm I2.4 kgml
wP9OOmc
Rotate the water pump and check that it rotates

freely.
wp9OOda
INSTALLATION OF FRONT COVER

Add clean oil.to the front gear train.
13-76
0
Caution: To prevent leakage from the crankshaft

seal lip and seal surface, do not leave any
oil on the seal.
Clean and dry the seal portion at the front of the

crankshaft.
Installer (795-799-1380)
Insert the plastic pilot installer in the lubricating oil

seal.
Set the lubricating oil seal with the dust lip facing
the outside, then set the seal on top of the service
tool of the installer (795-799-1380).
ac9tohd
Caution: Support the lubricating oil seal flange of

the front cover properly so that the lubri-
cating oil seal and front cover are not
damaged.
Set the lubricating oil seal facing the front of the

cover, then push it into the front cover from the
rear of the cover.
Push the lubricating oil seal in until the bottom of
the service tool contacts the front cover.
iehs
Coat the cover side only of the front cover gasket

with Three Bond 1207D.
Caution: Do not remove the lubricating oil seal from

the plastic seal pilot tool at this point. Use
the plastic seal pilot tool to guide the seal
onto the crankshaft.
Install the gasket and front cover to the engine.
13-77
0
10 mm
* -
After completing the tightening of the mounting
bolts, remove the alignment installing tool.
I0
-- -
0
6-
0
w: 24 Nm 12.4 kgm1
Install the front cover access cap and seal.

Turn first by hand, and when the seal is tightly fit-
ted and does not rotate, use a filter wrench (fuel
and filter cartridge removal jig) and rotate a fur-
ther 180” to tighten.
sc9cvhc
INSTALLATION OF CYLINDER
HEAD AA
Clean the surface of the cylinder head and block,
and be careful not to chip or gouge it.
Mallet
If the 2 cylinder head dowels were removed, in-

stall them. Push the dowels into the bottom of the
dowel hole.
Caution: Check that the gasket is properly aligned

with the block hole.
Put the head gasket on top of the dowel pins.
13-78
0
Set the cylinder head carefully on top of the block @JB

and fit it on the dowel pins.
@@
4-cylinder engine - 36 kg
6-cylinder engine - 51.3 kg
INSTALLATION OF PUSH ROD

Insert the push rod into the valve tappet.
pr900ht
Add oil to the push rod socket.
INSTALLATION OF ROCKER LEVER ,

Add oil to the valve stem.
kn9vawe
14 mm, flat-headed screwdriver
Completely loosen the rocker lever adjustment RI

screw.
rh9sswa
Caution: Align the rocker lever stand with the

dowel.
Add oil to the thread of the 8 mm holder mounting e

bolts and the bottom of the head of the mounting 0 )
bolts.
Install the mounting bolts and tighten by hand.
Add oil to the thread of the 12 mm holder and head

mounting bo!ts and the bottom of the head of the
mounting bolts.
13-80
0
Add oil to the thread and bottom of the head of the e

other mounting bolts. b
0
Install the mounting bolts and tighten by hand. _
kn9cswd
TIGHTENING OF CYLINDER HEAD

Tighten the cylinder head mounting bolts in the
kn 19csma
0<
Tighten the mounting bolts in the order given above
to 90 Nm 19.2 kgm).
Check in the order given above that the

the mounting bolts is 90 Nm I9.2 kgm}. torque
OfK 0
Scsma
13-81
0
Tighten only the 6 long mounting bolts (No. 4, 5,

12,13,20,21) in the number order to 120 Nm (12.2
kgm}.
Ad3dAhA kn9csoe
Tighten the mounting

further 90”.
bolts in the order given a
0\
(-
0\
To check that all the mounting bolts have been 7
turned 90”, check that the torque of the tightening
bolts is 136 Nm 113.9 kgm). When tightening the
mounting bolts to 136 Nm 113.9 kgm1, loosen only
that bolt and tighten again according to the proce-
dure given above.
13 mm
Tighten the 8 mm holder mounting bolts.
m: 24 Nm (2.4 kgm}
rh9csoa
13-82
0
ADJUSTING VALVE CLEARANCE

Tighten the valve adjustment screw until it contacts
the push rod socket. Then loosen one turn.
Set the No. 1 cylinder to the TDC position.
Remove the meshing of the timing pin.
Clearance gauge
Clearance between valve stem and rocker lever
Intake valve Exhaust valve

0.254mm 0.508
The clearance is correct if some resistance is felt

when the clearance gauge is pulled through the
space between the valve stem and rocker lever.
Adjust the valves as shown in the diagram.
Tighten the locknut, then check the clearance again.
m: 24 Nm I2.4 kgm)
13-83
0
Caution: At TDC compression stroke

(timing pin meshes) A
Carry out Step A of the procedure for set-
ting the valve for the No. 1 cylinder.
a
Step A - 4-cylinder engine
Valve
Cylinder I = intake E = exhaust
1 * *
2 *
3 * 4 3 2 1
4 rh9lvsb
(* = set) (- = not set)
Step A - g-cylinder engine
Valve
1 * *
2 *
3 *
4 * 6 6 4 3 2 1
5
6 rh9vaub
(* = set) (- = not set)
At TDC +360” (timing pin does not mesh)

Carry out Step B of the procedure for setting the
valve for the No. 1 cylinder.
Make marks on the crankshaft and front cover. Ro-

tate the crankshaft one turn.
er900wu
Step B - 4-cylinder engine
Valve
1
2 *
3 *
4 * *
(- = not et)
3 2 1
(* = set)
rh9vaua
13-84
0
Step B - 6-cylinder engine
E I I E I E
Valve
Cylinder I =intake E zexhaust
1
2 *
3 *
4 +
5 * 6 5 4 3 2 1
f? * *
rh9vauc
(* = set) (- = not set) I
INSTALLATION OF FUEL INJEC- 4~

TION NOZZLE @@
Coat the thread of the injector mounting nut and
the space between the head of the nut and injector
body (A) with seizure prevention agent. Be careful
not to let the seizure prevention agent enter fuel
drain hole (B).
4 f i9numa
i-: I
CD
Install the sealing washer to the injector.
Use only one sealing washer.
Caution: If the area between the washer and the

injector is coated thinly with clean 15W-
40 engine oil, it will help to prevent the
washer from falling out during the instal-
lation.
f iSwaP
24 mm deep well socket

RI
Tighten the injector.
Tighten the injector nozzle nut. q$
w: 60 Nm (6.1 kgml @@
Caution: Set so that the protruding portion at the

side of the nozzle is facing the injector, and 0q
fit it in the notch in the cylinder head.
_) \ \\ vfigh:nr
13-85
0
Caution: Depending on the socket, it may damage

the seal surface at the fuel drain outlet A
port.
INSTALLATION
HEAD COVER
OF CYLINDER
la
-
@ f i9toba
16mm
Install the gasket, valve, O-ring, and special mount-

ing bolts.
m: 24 Nm I2.4 kgm}
INSTALLATION OF INTAKE MANI-

FOLD COVER
LG-7 sealant
Coat the mounting bolts with sealant as shown in

the diagram.
Install the manifold cover, gasket, and mounting
screws.
Do not tighten the mounting bolts until the high-
pressure line bracket is assembled.
/ I,
im9cs ha
INSTALLATION OF AFTERCOOLER
(ENGINES WITH AFTERCOOLER)
LG-7 sealant
Coat the mounting bolts with LG-7 sealant as

Install the aftercooler. Do not tighten the mount-
ing bolts until the high-pressure fuel line bracket is
installed.
13-86
0
INSTALLATION OF LOW-PRESSURE
FUEL PIPING
17 mm
Install the fuel supply line of the Bosch A or Zexel

A fuel injection pump.
m: 25 Nm 12.5 kgm}
INSTALLATION OF FUEL DRAIN PIPING

IOmm
Use a new sealing washer for the fuel drain mani-

fold.
Install the fuel drain manifold.
m: 9 Nm (0.92 kgm}
INSTALLATION OF AIR BLEED PIPING

12 mm
Connect the air bleed hose to the Bosch A or Zexel

A fuel injection pump.
m: 10 Nm {I.0 kgm)
Installation of high-pressure fuel piping
Assemble the high-pressure fuel line.

INSTALLATION OF CRANKSHAFT
PULLEY, VIBRATION DAMPER
15 mm
Install the crankshaft pulley/vibration damper.
m: 125 Nm i12.7 kgm}
INSTALLATION OF FAN HUB

IO mm
Install the fan hub.
m: 24 Nm I2.4 kgm}
fa9OOht
13 mm or 14 mm
Install the fan hub pulley.
Tightening torque value
IO mm mounting bolt - 43 Nm (4.4 kgm}
hb
INSTALLATION OF BELT
TENSIONER
5 mm hexagon wrench
q
d/$
Install the tensioner bracket to the cylinder head.
@@
Tighten the screws of the socket head.
w: 24 Nm 12.4 kgm}
0(x
fa9bkha
13-94
0
13 mm
Set the belt tensioner on the bracket and secure it

with the mounting bolts.
w: 43 Nm {4.4 kgm}
Caution: There are also tensioners that are tight-

ened by bolts to the bracket at two places.
Install to the specified position.
INSTALLATION OF WATER INLET

Caution: Do not tighten at this point. Avoid radial
misalignment and overload on the bot-
tom support mounting gear on the alter-
nator. Leave the mounting bolts loosened
until the alternator parts are installed.
Install the cooling water inlet port connection and

sealing ring.
INSTALLATION OF ALTERNATOR
10 mm
Assemble the alternator bracket to the thermostat

housing.
w: 24 Nm (2.4 kgm}
Set the alternator on the bracket, and secure with

the mounting bolts and spacers.
Do not tighten at this point.
lllcsme
Caution: Do not tighten at this point. Avoid radial

runout and overload on the bottom sup-
port mounting lug of the alternator.
Leave the mounting bolts loosened until
the alternator parts are installed.
Install the alternator link.
:smd
Check the alternator pulley visually or use a straight

edge to check if the center is aligned with the other
pulleys and that it is parallel to the front face of the
block.
After assembling all parts, tighten the mounting

bolts in the following order.
Alternator bracket mounting bolts for alter- u

nator
Alternator mounting bolts for bottom brace
Cooling water inlet port mounting bolts for
alternator
Block mounting bolts for cooling water inlet
Port
Caution: The size of the wrench and the torque
‘value depend on the alternator manufac-
turer and the model. For details of the
torque value, see Engine Components.
INSTALLATION OF BELT
3/S inch square drive
Raise the tensioner and install the belt.
Operating hint:
If it is difficult to install the drive belt (the belt

may be too short), set the belt on top of the
grooved pulley and supportthe tensioner while
sliding the belt over the water pump pulley.
13-96
0
DISASSEMBLY AND ASSEMBLY REPLACEMENT OF TURBOCHARGER
REPLACEMENT OF
TURBOCHARGER (ENGINE
WITH TURBOCHARGER)
Preparatory work
Remove the connection of the charge air
cooler hose.
Remove the connection of the boost capsule
actuator hose.
Remove the connection of the intake and ex-
haust pipes.
REMOVAL
10 mm
Remove the bolts from the oil drain tube.
16 mm
Remove the connection of the oil supply line.
Caution: For engines assembled after June 1993, a

copper gasket may be used at both ends
of the turbocharger lubrication oil supply
line. When removing the line, always re-
place the washer.
Remove the intake manifold pressure supply line

from the boost capsule.
15 mm and 7/16 inch
Remove the exhaust clamp, turbocharger, and gas-

ket.
INSTALLATION
Install a new gasket, then coat the mounting stud
with seizure prevention compound.
15 mm
Install the turbocharger. /

it-
or
m : 45 Nm (4.6 kgm1
01
Di
uL
U[
tb9skha
10 mm and 7/16 inch
Use a new gasket and connect the oil drain tube.
m : 24 Nm I2.4 kgm1
0K
13-102
0
Using a depth gauge (795-790-18001, measure the

end clearance of the turbocharger shaft.
Push the rotor assembly away from the depth
gauge.
Set the depth gauge to 0.
Push the rotor assembly in the direction of the
depth gauge and note down the reading.
Play in axial direction

mm
0.03 Min
0.08 Max
0
Push the compressor impeller by hand in the di- s
rection of the compressor housing.
Install a wire clearance gauge at the point of mini-
mum clearance between the impeller and the hous-
ing, and measure the clearance.
Note down this clearance.
tb200te
0a
Leaving the clearance gauge in the same position,
push the turbine wheel away from the compressor
housing by hand.
Install the wire clearance gauge at the same posi-
tion.
Note down this clearance.
Subtract the small clearance from the large clear-
ance.
Clearance in radial direction

mm
0.30 Min tb200tf

0.46 Max
If the clearance in the radial direction is not within @

the above specification, assemble the turbocharger
again.
13-105
0
DISASSEMBLY AND ASSEMBLY REPLACEMENT OF AFTERCOOLER, GASKET
AFTERCOOLER, GASKET
(ENGINE WITH AFTERCOOLER)
Preparatory work:
l Remove the connection of the starting aid
used for starting in coldweather.
l Remove the air crossover tube.
l Drain 2 liters (2.1 US quarts) of coolant.
REMOVAL
8mm
Remove coolant supply tube (I) and coolant return
tube (2).
10 mm
Remove the aftercooler housing and gasket.
I
at9hsma
CLEANING
Clean the seal surface.
Caution: Be careful not to let the remains of the

gasket or other dirt enter the engine.
13-106
0
INSTALLATION
10 mm
Caution: The hole shown in the diagram is a

through hole, so coat the bolt with liquid
teflon sealant.
Install the aftercooler housing and a new gasket.
m: 24 Nm 12.4 kgm}
8mm
Install coolant supply tube (I) and coolant return

tube (2). Install air crossover tube (3).
w: 8 Nm IO.82 kgm}
Caution: Always vent the engine and aftercooler

and make sure that air is not trapped A
when the system is filled.
Prepare a 50:50 mixture of water and ethylene gly-

col antifreeze, and fill the cooling system.
Remove
surface.
the gasket material from the mounting
\
u
Warning: When carrying out steam cleaning, al-
ways use protective clothing, safety
glasses, and face shield. Contact with
A
the hot steam can cause serious burns.
Clean the aftercooler assembly with detergent

steam, then dry with compressed air.
or
\
q
I
at900eb
13-l 07
0
CLEANING AND INSPECTION

Check the aftercoolervisually to confirm that there
0s
are no cracks or damage. If there are any cracks or
damage, replace the aftercooler.
Testing aftercooler core pressure

(@I%
Install a hose, hose clamp, and solid pipe plug (I) @
to the inlet tube.
Install a hose and hose clamp (2) and air pressure
B
gauge (3) to the outlet tube.
Connect the adjusted air supply to the air pressure
gauge. 0
@
Air pressure: 552 kPa (5.6 kg/cm3
Insert the aftercooler in a water tank.

If bubbles appear, the core is damaged, so replace
the aftercooler. _
Remove the aftercooler from the water tank.
Remove the test equipment.
Dry the aftercooler with compressed air.
at900fb
ASSEMBLY
Caution: The aftercooler is an integrated assem-
bly, and cannot be reassembled. If any
A
attempt is made to repair the aftercooler
core, the water flow will be reduced, and
this will lead to future damage of the
engine.
@
For details, see “Cleaning and inspection of
aftercooler assembly for reuse”.
at9OOkd
13-l 08
0
REPLACEMENT OF INTAKE CONNECTOR
AIR CONNECTOR
DISASSEMBLY AND ASSEMBLY REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET
REPLACEMENT OF INTAKE
CONNECTOR
REMOVAL AND INSTALLATION

8 mm or screwdriver
Loosen the hose clamp and prepare so that it is

possible to remove the crossover tube from the
hose position.
When installing the crossover tube, use a new hose
and clamp if necessary.
w : 8 Nm IO.82 kgm}
AIR CONNECTOR
CLEANING
Clean the aftercooler assembly with detergent or

steam, then dry with compressed air.
z
%
6
INSPECTION
Check the turbocharger compressor V-band outlet
and air supply pipe connection visually to check
that there are no dents or fretting.
032
If there are any defects or damage, replace the tur-
bocharger compressor housing or air transfer pipe.
tblcrmb
REPLACEMENT OF INTAKE
MANIFOLD COVER, GASKET
Preparatory work:
Remove the connection of the starting aid

used for starting in cold weather.
Remove the connection of the charge air
cooler hose.
Remove the high-pressure fuel line.
13-l 09
0
DISASSEMBLY AND ASSEMBLY REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET
REMOVAL
10 mm
RI
Remove the manifold cover, gasket, and grid heater.
im9cvmb
I I
\
CLEANING
Clean the seal surface.
Caution: Be careful not to let the remains of the

q
gasket or other dirt enter the engine.
INSTALLATION
10 mm
Install the cover and a new gasket.
w: 24 Nm I2.4 kgm)
Assemble the intake pipe and connect the starting

aid used for starting in cold weather.
m: 8 Nm IO.82 kgm}
13-110
0
DISASSEMBLY AND ASSEMBLY AIR CROSSOVER TUBE
AIR CROSSOVER TUBE

CLEANING
A
Clean the air crossover tube with detergent or

steam, then dry with compressed air. \
q
INSPECTION
Check the air crossover tube visually for cracks or
damage. Replace the tube if there is any damage.
Check the hose sealing surface visually for dents
or damage. Replace any damaged part.
ca9t bsa
13-111
0
DISASSEMBLY AND ASSEMBLY EXHAUST GROUP
2
EXHAUST GROUP
DISASSEMBLY AND
ASSEMBLY DRAWING
II xm3OOen
Index No. Part Name WtY Remarks
1 Exhaust external connection brace 1

2 Hexagonal mounting bolt 4
3 Exhaust external connection 1 90” turbocharger exhaust elbow
4 V-band clamp 1
5 Pipe plug 1
6 Turbocharger gasket 1
7 Stud 4
8 Nut 4
9 Exhaust manifold 1
11 Manifold gasket 6
13-112
0
DISASSEMBLY AND ASSEMBLY EXHAUST MANIFOLD
OUTLINE OF EXHAUST MANI-

FOLD
The 102 series engine uses a pulse type manifold
with a divided turbocharger inlet passage (outlet
port of exhaust manifold) installed. To match the
various restrictions on installation space, it is pos-
sible to install the turbocharger in various places.
The turbocharger can be installed at the middle,
front or rear, or high or low positions.
Machine the seal surface to the flatness specifica-

tion, or polish it to correct any warping.
13-113
0
REPLACEMENT OF EXHAUST MANIFOLD, GASKET
Put a straight edge over the exhaust port. The

maximum permissible clearance between the
manifold and the straight edge is 0.10 mm.
REPLACEMENT OF
TURBOCHARGER xm9OOna
REMOVAL
Remove the intake and exhaust piping.
16 mm and 19 mm
Remove the turbocharger oil supply line from the

turbocharger and oil filter head.
Screwdriver or 7/16 inch
Remove the air crossover tube or charge air cooler

piping from the turbocharger.
10 mm
Remove the oil drain tube from the bottom of the

turbocharger.
t b9csma
Screwdriver
Remove the hose from the turbocharger westgate.
t b9homc
15 mm
Remove the turbocharger mounting nut, turbo- /

charger, and gasket. cl:
Caution: For details of the procedure for inspec- or
tion of the turbocharger, see Component.
01
illi
u1
U[
tb9akha
INSTALLATION
Install the turbocharger gasket, then coat the
mounting stud with seizure prevention agent.
13-l 18
0
15 mm
Install the turbocharger.
Q~TJ: 45 Nm I4.6 kgm}
13 mm, 7/16 inch
If necessary, loosen the turbine housing mounting RI-

bolts and compressor housing clamps, align with
the turbocharger drain tube mount, and set the
bearing housing in position.
IO mm
Install the turbocharger oil drain tube and gasket.
m : 24 Nm {2.4 kgm}
13 mm
If the turbine housing mounting bolts were loos-

ened, tighten them.
m : 20 Nm 12.0 kgm}
7/16 inch
If necessary, loosen the compressor housing clamp,

align with the air crossover tube, and set the hous-
ing in position.
Tighten the clamps.
m: 8 Nm 10.82 kgm}
Screwdriver or 7/16 inch
Install the air crossover tube or charge air piping.

Tighten the clamp.
m: 8 Nm (0.82 kgm}
Caution: Lubricate the turbocharger.
Add 50 - 60 cc of clean oil through the oil inlet port

A
fitting at the top of the turbocharger and rotate the k
4
turbocharger impeller to send oil to the bearing. cl
t b9OOwb
16 mm and 19 mm
Install the oil supply line.

Tighten the fitting securely.
w: 35 Nm (3.6 kgm}
13-120
0
Screwdriver
Connect the hose to the turbocharger westgate. El
a/$
@@
TURBOCHARGER MOUNTING
STUD (ENGINE WITH
TURBOCHARGER)
REPLACEMENT
0a
Inspect the stud thread to check that there is no
damage.
When replacing the stud, use 2 nuts jam locded on
the stud.
Before installing the stud, coat the thread with sei-

zure-prevention agent.
xm9boha
13-121
0
DISASSEMBLY AND ASSEMBLY CYLINDER BLOCK GROUP
CYLINDER BLOCK GROUP

DISASSEMBLY AND ASSEMBLY DRAWING
42
ck900s I
13-l 22
0
Index No. Part Name my. Remarks
45 Hexagonal cap screw 2 M8-1.25 x 20

46 Balancer housing 1
47 Needle bearing 2
48 Needle bearing 2
49 Needle bearing 2
50 Balancer shaft 1
51 Balancer shaft 1
52 Inner bearing race 6
53 Pin 8
54 Key 2
55 Balancer shaft gear 1
56 Balancer shaft gear 1
57 Balancer weight 3
58 Hexagonal head screw 10
59 Thrust collar 2
60 Thrust bearing plate 1
61 Thrust bearing plate 1
62 Hexagonal head screw (flange) 2
63 Idler gear 1
64 Needle bearing 1
65 Gear retainer 1
66 Socket head screw 2
67 Gear cover gasket 1
68 Gear housing 1
69 Gear housing cover gasket 1
70 Gear cover 1
71 Hexagonal head screw (flange) 4 M8-1.25 x 50
74 Square ring seal 1
75 Access hole cover 1
76 Data plate 1
77 Drive screw 2
78 Data plate 1
79 Drive screw 2
80 Square ring seal 1
81 Timing pin housing 1
82 O-Ring 1
83 Timing pin 1
84 Retaining ring 1
85 Round hexagonal screw (torx) 2 M5-0.8 x 17
86 Front crankshaft seal 1
87 Crankshaft pulley 1
13-124
0
OUTLINE OF CYLINDER BLOCK

GROUP
There are two types of engines in the 102 series: OUTLINE OF OIL SEAL
the 4-cylinder engine and the 6-cylinder engine.
The crankshaft seals on the 102 series engines all
Most of the parts are common for both the Ccylin- are of the Teflon lay-down lip (scroll) type. With
der engine and 6-cylinder engine (for example, pis- this type of seal, there is no spring behind the seal-
tons, rings, connecting rods, water pump) ing lip. The seal lip is a thin but sturdy Teflon piece.
Generally speaking, the parts that are different for Dry the Teflon seal before installing it. Do not add
the Ccylinder engine and 6-cylinder engine are the oil to the seal lip or shaft.
parts that differ because of the different number of
If the shaft is rotated 2 or 3 turns, a thin film of
cylinders (for example, crankshaft, block casting,
Teflon will flow out from the seal lip to the shaft.
cylinder head)
If the shaft or seal are not cleaned and dry, there
will be no flow of Teflon and this will result in leak-
OUTLINE OF CAMSHAFT
age from the seal.
The end clearance of the camshaft is determined
by the clearance between the camshaft and the
thrust plate.
Replace the camshaft if it is worn or if the fuel feed

pump lobe or valve lobe are worn. We do not rec-
ommend grinding of the camshaft lobe.
OUTLINE OF CRANKSHAFT
The crankshaft is a balanced, forged steel unit with
hardening treatment given for the whole thickness.
The crankshaft for the 4-cylinder engine has 5 main
bearing journals and the crankshaft for the 6-cylin-
der engine has 7 main bearing journals. Except
for the No. 4 journal, which has an upper bearing
shell with a flange, all the other upper main bear-
ing shells are the same. The upper bearing flange
controls the end thrust of the crankshaft.
When carrying out maintenance, an oversize main

bearing, thrust bearing, and connecting rod bear-
ing can be used. If any part requires grinding, we
recommend thatall the main bearings or connect-
ing rod journals should be ground.
OUTLINE OF CYLINDER BLOCK

The oil cooler, thermostat seat, coolant bypass line,
water pump volute, oil pump housing, water pump
inlet port, and bore type piston cylinder are installed
to the cylinder block. Space is provided between
the cylinders for use when maintenance is required
and room is left to make it possible to use a dry
liner.
13-l 25
0
REPLACEMENT OF FRONT OIL

SEAL
REMOVAL
Remove the drive belt.
%Q
Caution: If the crankshaft pulley is loosened be-

fore the belt is removed, the belt can be
removed easily.
fa9blma
15 mm
Remove the crankshaft pulley.
da9puma
Remove the front cover. For details of the proce-

dure. Q
%
Remove the oil seal from the gear cover. Support

the gear cover, set the oil seal facing to the front,
and push out from the rear of the cover.
ac9semb
13-126
0

K-I
Clean the gear cover seal bore and crankshaft sur- w
face, and remove any remaining seal or oil.
0s
Check the crankshaft for excessive wear.
Caution: If the crankshaft is excessively worn, a

service wear sleeve can be used.
INSTALLATION
Coat the outside diameter of the seal with a bead
of Loctite 277 or equivalent.
sc9sena
3824498 installer
Insert the plastic pilot installer in the oil seal.
Set the oil seal with the dust lip on the outside,
then set the seal on top of the service tool (part
number 3824499).
acltohd
13-l 27
Caution: Support the lubricating oil seal flange of

the front cover properly so that the lubri-
cating oil seal and front cover are not dam-
aged.
Push the lubricating oil seal into the front cover

from the back side of the cover toward the front
side of the cover. Push the lubricating oil seal until
the service tool bottoms against the front cover.
Coat the cover side only of the front cover gasket

with Three Bond.
Caution: Do not remove the lubricating oil seal from

the plastic seal pilot tool at this point. Use
the plastic seal pilot tool to guide the seal
onto the crankshaft.
Tighten the front cover mounting bolts. @I/$ > - -I
Remove the plastic pilot tool from the crankshaft. @@

I 6 -_ -
A
0 0
m: 24 Nm {2.4 kgm) --o-

O6
0 0 0
1 $ or
6
I
Install the crankshaft pulley. Do not tighten the

mounting bolts to the specified torque atthis point.
da9vuma
13-128
0
REPLACEMENT OF FRONT OIL SEAL
DISASSEMBLY AND ASSEMBLY REPLACEMENT OF REAR OIL SEAL
Install the drive belt.
fa9blma
w: 0(K
Tighten the crankshaft pulley mounting bolts.
123 Nm I12.7 kgm}
REPLACEMENT OF REAR OIL SEAL

Preparatory work:
l Remove the transmission.
l Remove the flywheel.
fw9OOha
l/8 inch drill
Make 2 holes 180 x apart in the seal carrier.

No. 10 sheet metal screw, slide hammer dent

puller
Remove the rear seal.
Caution: To prevent leakage from the seal, make

sure that there is absolutely no oil on the A
\
crankshaft seal lip or seal surface.
Clean the crankshaft seal surface and dry it. q
Install the seal pilot (included in the replacement

kit) to the crankshaft. Push the seal against the
pilot and crankshaft.
Remove the seal pilot.
ks9sehb
Using the alignment tool, install the seal to the

proper depth in the housing. Tap with a hammer
to knock the seal into the housing to a point where
the alignment tool contacts the housing.
Tap the tool at the 12 o’clock, 3 o’clock, 6 o’clock,
and 9 o’clock positions to push the seal in uni-
formly. Be careful not to bend the seal carrier.
bD9OOvf
13-130
0
19 mm
Install the flywheel. Tighten the mounting bolts in

the order shown in the diagram.
w: 137 Nm 114.7 kgm}
fh900oa
Install the clutch, transmission, and starting mo-

tor. Run the engine and check for any leakage.
OUTLINE OF PISTON
The piston body is made of cast aluminium and
there are three ring grooves. The top ring groove
on turbochanged engines has a ni-resist insertwith
a keystone profile. The other pistons used in the
engine look the same from the outside, but they
are not interchangeable. Always check the part
number and use the correct piston when replacing
the piston.
OUTLINE OF VIBRATION DAMPER

A vibration damper is installed to the 6-cylinder
engine to control the torsional vibration of the
crankshaft. The vibration damper is designed so
that it can be used on particular engine models.
It is not economical to repair the vibration damper
in the field. If inspection shows that the damper is
defective, install a new damper or a reassembled
damper.
13-131
0
CHECK LIST FOR CYLINDER BLOCK GROUP
Flatness of head deck ....................................................................................... II
Inside diameter of main bearing ..................................................................... 0
Inside diameter of camshaft ............................................................................ 0
Inside diameter of tappet ................................................................................. cl
Accumulation of sediment in cooling water passage ................................... 0
Crankshaft seal wear surface ........................................................................... cl
Damage to rod and main journal .................................................................... q

Vibration damper index line and rubber parts .............................................. Cl
Visual check of damage to piston assembly ................................................. q

Measurement of piston skirt diameter ............................................................ 0
Piston ring clearance ........................................................................................ q

Measurement of inside diameter of piston pin ............................................. 0
Visual check of connecting rod assembly.. .................................................... c]
Clearance of main bearing ............................................................................... cl
Clearance of connecting rod bearing .............................................................. III
13-132
0
DISASSEMBLY AND ASSEMBLY CYLINDER BLOCK
CYLINDER BLOCK
INSPECTION BEFORE DISASSEMBLY
Clean the cylinder block with steam.
ck900ei
Check the cylinder block visually for damage

would prohibit reuse.
that
0
s
DISASSEMBLY OF CYLINDER BLOCK

3/8 inch square drive
Remove the pipe plug from the cooling water pas-

Fxl
sage.
0
6%
:md
11 mm
Remove the pipe plug from the oil passage.
;m ck9pxme
Drill motor, 3 mm drill bit, slide hammer, No. 10

thin plate screw
Make a 3 mm hole and remove the cup plug using

a slide hammer fitted with a No. 10 thin plate screw.
Remove the cup plug from the oil passage.
9eDmf
Punch, visegrips, hammer
Remove the large expansions

from the cooling water passage.
plug (58.06 mm) RI
Be careful not to knock the cup plug into the water
jacket. Be particularly careful with the plug at the
6%
Q
end of the block.
Operating hint: If it is found that the cup plug does
not rotate inside the bore, use a center punch, grip
the edge of the expansion plug, and pry against
the block to turn plug out.
Hammer, punch
Knock the plug into the water jacket, then remove

the small cup plug (25.07 mm).
Mechanical finger
Remove the plug from the cooling water passage

at the top of the block.
a00
-0 0
-A- ck900sf
13-134
0
Remove the cup plug from the camshaft bore.

G3
Q
ck9emi
Universal bushing installer

Remove the camshaft bushing.
CLEANING OF CYLINDER BLOCK

Using clean solvent and a brush, clean the main
oil drilling.
Using clean solvent and a brush, clean the cam bore

oil drilling from the main bearing. q
\
’
Using clean solvent and a brush, clean the bore of

the piston cooling nozzle.
\
q
Using clean solvent and a brush, clean the over-

head oil drilling from the main oil rifle.
\
q
\
q
Using clean solvent and a brush, clean the oil pas-
sage of the oil cooler
Gasket scraper
Clean the gasket seal surface.
13-136
0
Clean the combustion deck with a cleaning

equivalent, using diesel fuel or solvent.
pad or
\-
q
l&T ck900ej
Brush, No. 400 grit sandpaper, diesel fuel
Clean the cup plug hole. RI

\
q
The excessive deposit inside the acid-proof tank

can be cleaned off, but first remove the cam bush-
A
ing.
Accumulation of sediment in the cooling water

passage is a cause of engine overheating.
\
q
Check that the cooling water passage is normal.
I ck900ek
Warning: Take measures to protect yourself from

injury.
The block can be cleaned in a hot tank with soap

and water solution without removing the cam bush-
ing.
ck900el
After rinsing the block with clean solvent, dry it with

compressed air. q
\
I ck9OOes t
INSPECTION OF CYLINDER BLOCK

Inspect the glazing of the cylinder bore.
0a5
If there is no glaze on the surface, cross hatching
(mesh pattern) consisting of lines at 25” to 30” can
be seen at the top of the cylinder block.
@
If deglazing is necessary, see procedure.
De-G1 azed
Check the cylinder bore for damage or excessive

wear.
Measure the cylinder bore.
Diameter
mm
102.000 MIN
102.116 MAX
Tolerance: 0.038 mm
Taper: 0.076 mm
After the cylinder block has been rebored, an over-

size piston and ring (0.5 mm and 1.0 mm oversize)
can be used.
Measure the total flatness of the cylinder block.
End to end: 0.076 mm (0.003 in}

Side to side: 0.051 mm iO.002 in}
Check visually for any unevenness in places and

for incompleteness. If there is any problem, regrind
the cylinder head deck.
ck900td
13-138
0
Check the main bearing bore for damage or ab-

normal wear.
Install the main bearing, tighten the main bolts to
176 Nm (17.9 kgm), then measure the diameter of
the main bearing bore.
Caution: Note the measurement for the diameter,

and use it to determine the main bearing
clearance explained in procedure.
Diameter
mm
83.106 MAX
Remove the bearing and install the main bearing

cap. Tighten the main bearing mounting bolts to
176 Nm I17.9 kgml. Remove the bearing and mea-
sure the main bearing bore.
Diameter
mm
87.983 MIN
88.019 MAX
Check the camshaft bore without the bushing

check if there is any damage or excessive wear.
Diameter No. 1
mm
57.222 MIN
57.258 MAX
Measure the diameter of the camshaft bores from

No. 2 to No. 5.
Diameter No. 2-5

mm
54.089 MIN
54.164 MAX
A service bushing can be used. Use one if the wear

exceeds the limit.
Check the tappet bore for damage or excessive

wear.
Diameter No. 1
mm
16.000 MIN
16.055 MAX
Caution: If the cylinder head or cylinder block are @

not within the specification, machine the
surface that is out of the specification. For
details of the procedure for machining the
surface, see the Alternative Repair Manual
for resurfacing information.
REMOVAL OF GLAZE FROM CYL-

INDER BORE
DISASSEMBLY
Drain the coolant.
Remove the cylinder head.
Drain the lubricating oil.

Remove th,e oil pan.
I v oP9OOme
13-140
0
Remove the piston and connecting rod assembly.
INSPECTION
Measure the cylinder bore at points 25.4 mm {I in1
and 170.0 mm {5.5 in) from the top of the cylinder
block.
Max. bore diameter: 102.116 mm

Tolerance in bore: 0.035 mm -
Bore taper: 0.076 mm
Caution: If the wear of the cylinder bore exceeds

the specified limit, do not proceed with
in-chassis overhaul.
REMOVAL OF GLAZE
It is necessary to carry out finishing by removing
the glaze in order for the ring to seat with the sur-
face of the cylinder bore.
Caution: Do not seat new piston rings in cylinder

bores where there is glaze.
De-Glazed
Wrap the connecting rod journal with a clean cloth.

Cover the cloth with water-proof tape.
ks900w I
Place a clean towel around the upper main bear-

ing saddle and catch the residue and water that
comes out from the piston cooling nozzle.
I J mb9OOwe
Cover the tappet hole and oil hole at the top of the
cylinder block with water-proof tape.
'l ci 1.1-e
- .I
' ck9bdwo
On surfaces where the glaze has been properly re-

moved, a cross-hatch pattern consisting of lines at
an angle of 15 - 25” to the top of the cylinder bore / \
is formed.
13-142
0
Use a drill, fine flex hone, and a 50:50 mixture of

mineral oil and SAEBOW engine oil to remove the
glaze from the cylinder bore.
The angle of the cross-hatching depends on the

speed of the drill and the speed of perpendicular
movement of the hone.
ck9brxf
The diagram on the right shows the result when

the drill speed is too slow or the perpendicular
stroke is too fast.

the drill speed is too fast orthe perpendicular stroke
is too slow.
Caution: For the vertical stroke, move continuously

and smoothly along the whole length of
the cylinder bore.
Check the cylinder bore after IO strokes.

0
@f
ioto20
Strokes
CLEANING
Clean the cylinder bore with a concentrated mix-
\
q
ture of hot water and detergent.
ck9breh
Caution: Clean the cylinder bore immediately af-

ter removing the glaze.
Rinse the cylinder bore and remove the detergent.

Dry the cylinder block with compressed air.
ck9brei
After completion
ering the tappet
of cleaning, check if the tape cov-
and oil hole has been peeled off. 032
q
Add oil to a white cloth (check that the cloth has
no loose threads), then wipe the cylinder bore to
\
check that it is clean. If there is still residue from
the grit, continue the cleaning operation until it is
all removed. Wash the cylinder bore with deter-
gent, then dry the cylinder block with compressed
air.
13-144
0
q
Check if the cover has been removed from the pis-
ton cooling nozzle. \
Remove the protective tape and cloth, then clean

the crankshaft journal.
Oej
q
Using detergent and a brush, clean up the residue \
that has been thrown off the camshaft. -
Caution: Check for wear and damage to the cam- @
shaft lobe and tappet surface.
ASSEMBLY
q$
Install the piston and connecting rod assembly.
@@
,@+
Install the oil pan.

Install the cylinder head.
Fill the oil pan. Fill the radiator with coolant.
Run the engine until it reaches the normal operat-

ing temperature, then check for leakage.
REMOVAL OF GLAZE FROM CYLINDER

BLOCK
Do not seat the new piston ring in the glazed cylin-
der bore.
Deglazing means making the bore rough, so it is
easy for the ring to stay in position. If the deglazing GI azed
is carried out properly, the bore size will not change.
If the glazing is not carried out properly, the size of
the bore will change.
De-G1 azed
If deglazing of the surface is carried out correctly,

a cross-hatch pattern of lines at an angle of 15” to
25” to the top of the cylinder block can be seen.
13-l 46
0
Use a drill, fine flex hone, and a 50:50 mixture of

mineral oil and SAE30W engine oil to remove the
glaze from the cylinder bore.
ck9OOwh
The angle of the cross-hatching depends on the

speed of the drill and the speed of perpendicular
movement of the hone.
2 1 Stroke (t + I l/Par Second ckgbrxf

I

the drill speed is too slow or the perpendicular
stroke is too fast.

the drill speed is too fast or the perpendicular stroke
is too slow.
Too
Slow
Caution: For the vertical stroke, move continuously

and smoothly along the whole length of
the cylinder bore.
Check the cylinder bore after 10 strokes.
Caution: Be careful not to make the bore too wide.
To remove small grooves or to correct small errors

in the taper, use a sizing hone.
Taper: 0.076 mm
Minor
Grooves
or Taper
Use the sizing hone in the same way as the flex _ [

hone. -
Check the bore after 10 strokes.
1 Stroke
It 4)
Per Second
q
Clean the cylinder bore immediately with a con- \
centrated mixture of hot water and detergent.
Rinse the cylinder bore, then dry the cylinder block
with compressed air.
ck9breh
13-148
0
CYLINDER BLOCK
0a
Add oil to a white cloth (check that the cloth
has no
loose threads), then wipe the cylinder bore
to check
that it is clean. If there is still residue from
continue the cleaning operation until it is
moved.
the grit,
all re- \
El
Clean the block with solvent.

Use a brush to clean the oil passage. \
u
REPLACEMENT OF PLUG
REMOVAL
Remove the pipe plug.

Use a spray cleaner (part number 337543
equivalent,
3) or
and clean the pipe plug thread and
\
q
tapped bore.
Check the thread of the pipe plug visually for dam-

age.
Check the tapped bore visually for damage.
032
INSTALLATION
Coat the thread with pipe plug sealant (part num-
ber 3375066) or the equivalent.
Install the pipe plug and tighten it.
0T
For details.of the tightening torque value, see the
table below on the right.
Tighten the pipe plug to the applicable torque.

0(K Pipe Plus Torque Values
Torque
In Cast Iran or
Steel Cmonents
N-m Ift-I bal
6. I LO.321 5 I45 in-lb1 15 1101
10. 4 lo.411 15 1101 ii i151
13.1 [O. 541 20 I151 25 1201
17.3 IO.661 25 [201 36 I251
21.6 10.651 35 1251 55 1401
26.7 Il.061 46 [351 76 I551
1 33.5 11.321 60 1451 95 1701
I ‘A 42.2 [I.661 75 I651 116 1651
1‘A 48. 3 II.901 65 1661 135 [IO01
ck8ppo
REPLACEMENT OF CAP
REMOVAL q
\
Clean the dirt away from around the cup plug.
13-150
0
Punch, vice grip

Remove the large cup plug (58.06 mm) 12.29 in]
from the cooling water passage.
Be careful not to let the expansion plugs out, in
particular the plug at the end of the cylinder block,
enter the water jacket.
Operating hint: If it is found that the cup plug does
not rotate inside the bore, use a center punch, grip
the tip of the cup plug, and use the block as a lever
to remove the plug.
CLEANING
Use Scotch-Brite or equivalent to clean the expan-
sion plug hole thoroughly.
q
\
Use spray cleaner (part number 3375433) or the

equivalent to carry out final cleaning of the bore.
Check the cup plug bore visually for damage.
INSTALLATION
Caution: If too much sealant is used, it will flow
back to the engine and damage other
A
component. Leave the sealant to dry for
\
at least 2 hours before starting the en- t
gine. \
+\
Coat the outside diameter of the expansion plug
and the inside diameter of the mounting bore with G
a 2 mm WI6 in) bead of expansion plug lock N
seal (part number 3375068) or the equivalent.
@
I ck9epwc
73-751
0
Use a socket of a suitable depth as a driver and

install the cup plug.
Make the tip of the cup plug 0.5 - 1.0 mm IO.020 -

0.040 in} deeper than the inlet port chamber of the
bore, and install the cup plug.
Caution: Do not make the installation of the cup

plug too deep. If it is impossible to in-
stall the cup plug straight and flat, replace
it with a new cup plug.
Remove the cup plug from the oil passage.
INSTALLATION OF CUP PLUG

Coat the area around the plug with Loctite 277.
ck9ePhc
13-152
0
Knock the plug in until it contacts the bottom of

the bore.
0
After adding oil to the engine, start the engine and s
check for oil leakage.
Stop the engine and check the oil level.
ck9eDva
Remove the cup plug from the cooling water pas-

sage as shown in the diagram.
Coat the area around the cup plug with Loctite 277.
Knock in the plug until the edge of the plug be- 4~

comes the same as the counterbore in the block. @Q
ck9evhd
INSTALLATION OF CAP AND PLUG

Machine the bore of the block expansion plug to
standard inch dimensions (1 l/16 inch, l-1/4 inch,
etc.)
To press fit the cup plug properly into the bore, the
expansion plug must be larger than the diameter
of the bore, and the expansion plug driver must be
smaller than the diameter of the bore. Therefore,
the expansion plug and the driver are not made to
the standard inch sizes.
The size of the plug driver is determined by the

dimension of the bore being used (use a driver of
less than 1” for a 1” bore). The expansion plug is
displayed as a Cummins part number (for refer-
ence, the dimensions are also given).
Before installing, coat the outside circumference

of the cup plug with LT-4.
Push in the cup plug until the outside edge is level

with the counterbore hole in the block.
ck9ephd
Coat the thread with LG-7 pipe sealant or the

equivalent.
Install the pipe plug and tighten it.
For details of the tightening torque values, see the
chart on the next page.
ck9pxha
13-l 54
0
0T
Tighten the pipe plug to the applicable torque. r Pine Plu rorque Values
Iize
Thread
ACUN~I m
Thread O.D.
In. mm IW N*m [ft.lbsl N-m Ift-lbsl

l/l6 8.1 lO.321 5 [45in-lb1 15 I101
l/8 10.4 10.411 15 I101 20 I151
114 13.7 10.541 20 I151 25 PO1
3/8 17.3 10.681 25 I201 35 1251
l/2 21.6 IO.851 35 I251 55 MO1
314 26.7 H.051 45 I351 75 I551
1 33.5 Il.321 60 I451 95 I701
1 l/4 42.2 Il.661 75 [551 115 I851
11/z 48.3 f1.901 85 I651 135 11001
ck8ppoa
Driver (795-799-12301, driver (795-799-12201
Set the cup plug in position.

Front face of block
-0
1. Cup plug 6732-21-1830 (58.06 mm)
2. Cup plug 6732-21-1810 (17.73 mm1 -0
ck9ephf
Driver (795-799-1230)
Position of pipe plug and cup plug.

Right side of block
1. Cup plug 6732-21-1830 j58.06 mm)

2. Pipe plug 0.50 inch {l/2 in)
Driver (795-799-1230), driver (795-799-1220)
Position of cup plug.

Rear of block
1. Cup plug 6732-21-1830 (58.06 mm)

2. Cup plug 6732-21-1810 I17.73 mm}
ck9ephh
Position of pipe plug and cup plug.
Left side of block
1. Cup plug 6732-21-1810 (17.73 mm}

2. Cup plug 6732-21-1820 (25.75 mm)
3. Cup plug 6732-21-5530 (9.80 mm}
4. Cup plug 6732-21-6160 132.03 mm}
5. Pipe plug 0.125 in (l/8) NPTF hexagonal head
ck9Pxhz
INSTALLATION OF CAMSHAFT CUP
ck9epwd
Insert an O-ring, then set the protruding part of the

plug on the outside and set in position.
I ck9ephj
Large drift, hammer

RI
Using the large drift and hammer, spread the plug
out.
13-l 56
0
0s
Spread the plug out until the protruding surface
becomes level with the block.
INSTALLATION OF CAMSHAFT BUSH-

ING
Align the camshaft bushing and block with the oil
hole, then make marks.
ck9bswa
Coat the end of the bushing to be installed at the

rear of the bore with LT-4. As shown in the dia-
gram, coat a 270” arc of the diameter of the bush-
ing with LT-4. Be careful not to coat with LT-4 near
the oil hole or directly opposite the hole.
ca9bswe
Universal bushing installer
Install the camshaft bushing so that it is flat with

the block.
033
Check that the oil hole is aligned.
A rod of diameter 3.2 mm (0.126 in) must pass

through the hole.
Measure the installed camshaft bushing.
Camshaft bushing bore

mm
54.107 Min
54.146 Max
9brja
REPLACEMENT OF DIPSTICK TUBE

Pliers
RI
If the dipstick is loose or damaged, remove it from
the cylinder block.
IsOtbmb
Coat the new dipstick tube with LT-4.
13-158
0
CYLINDER BLOCK
DISASSEMBLY AND ASSEMBLY CRANKSHAFT
STORING CYLINDER BLOCK

If the block is not to be used immediately, apply oil
to the whole surface to prevent rust.
ck900eo
CRANKSHAFT
Preliminary inspection
Drain the lubricant
of main bearing
and remove the oil pan. c%
Q
Caution: Before removing the main bearing cap,
check that there are marks clearly show-
ing the position of the cap on the oil
cooler side of the main bearing cap.
oP9OOmf
Check the main bearing and crankshaft journal vi-

sually. Remove the No. 2 and No. 3 caps, and check
the crankshaft journal for signs of overheating,
deep scratches,
damage, ?? the
and other damage. If there is no
other main bearings at this stage. 0a
mb9OOkb
032
Check the main bearing cap for dents, cracks, and
other damage.
mb9OOs
0a
Check the crankshaft journal for deep scratches,
signs of overheating, and other damage.
Caution: If the crankshaft journal or main cap are

damaged, remove the engine and carry
out an overhaul.
REPLACEMENT OF MAIN BEAR-

ING
On the 6-cylinder engine, remove all the main bear-
ing caps except the No. 1 and No. 7 main bearing
caps. On the 4-cylinder engine, do as shown in \
the diagram. /
mb9OOhs
Using a pin, rotate the upper bearing from between

the crankshaft and cylinder block, and pull it out.
When making the pin, grind a 6 mm mounting bolt
to the dimensions shown in the diagram.
mb9toxa
13-l 60
0
Install the pin in the crankshaft oil hole. Rotate the

crankshaft and push the pin towards the end of the
main bearing on the opposite side from the tank.
Remove the main bearing.
Repeat the same procedure to remove the other
main bearings.
0ai
Check the main bearing cap and main bearing
crankshaft journal.
Measure the size of the removed main bearing, and

prepare a bearing of the same size for installation.
For details of the dimensions of the standard and
undersize main bearing journals, see the section @
on using the base engine components.
0.25mm LOO9 in.)
0.50mm LO19 in.)
0.75mm LO29 in.)
l.OOmm LO39 in.1
Caution: Do not put oil on the side facing the cyl-

inder block.
Coat the new upper main bearing with Lubriplate

105.
I cx9besb
13-161
0
Set the new main bearing in position on the crank- 4~

shaft, then install as strongly as possible by hand. @a
mb9behd
Using the pin, check that the main bearing is

aligned with the cylinder block, and push the main
bearing slowly. Check that the tongue of the main
bearing has entered the notch.
v mb9behf
Caution: Check that the pin has not slipped under

the bearing. A
l9tobc
Install the lower main bearing to the main bearing

cap.
Coat the main bearing with Lubriplate 105@.
13-162
0
DISASSEMBLY AND ASSEMBLY CRANKSHAm
23mm
Caution: Set the cap numbers facing the oil cooler

side of the engine, and check that they
have been installed correctly in number
order.
Install the main bearing cap after installing each

upper main bearing in order to keep the main bear-
ing in the specified position while installing the
other upper main bearings.
Tighten the mounting bolts to 50 Nm {5.1 kgm1. At
this point, do not tighten to the final tightening
mb900nh
torque.
Repeat the same procedure to remove and install

rear main bearing caps No. 5 and No. 7.
mb9bemd
Flat-headed screwdriver
Caution: Be careful not to let the screwdriver dam-

age the crankshaft or cylinder block.
Caution: There is no hole in the journal at front

main bearing No. 1, so it is impossible to
use the pin when replacing the bearing.
Use a flat-headed screwdriver. Tap the end of the

bearing lightly to loosen it from the cylinder block.
Push the main bearing with your finger and turn
the crankshaft to push the main bearing out.
Add oil to the main bearing and install it.

Using a screwdriver, rotate the crankshaft and push
in the main bearing to the specified position.
CLEANING OF CRANKSHAFT -I
Clean the crankshaft oil drilling with a brush. \

u
Rinse with detergent, then dry with compressed
air.
q
Clean the oil seal wear surface with diesel fuel and \
cloth.
ks9OOwo
INSTALLATION OF CRANKSHAFT
Inspect the crankshaft
age and grooves.
seal wear surface for dam-
033
If there is any groove in the shaft, install a wear
sleeve.
Check the connecting rod and main journal for deep

scratches and overheating.
02sa
Deciding main bearing clearance
Measure the diameter of the main bearing and

decide the main bearing clearance. @
Diameter of main bearing journal

mm
82.962 Min
83.013 Max
Tolerance: 0.050 mm
Taper: 0.013 mm ksqnftti
Bearing clearance = Diameter of main bore with
installed bearing - diameter of crankshaft main
journal
Maximum bearing clearance limit: 0.119 mm
REPLACEMENT OF CRANKSHAFT
GEAR
The crankshaft gear cannot be removed inside the

chassis.
65%
Remove the crankshaft gear.
Use a heavy-duty puller. 8 Q
v 7
I
Ib
ks9aemc
032
Remove any flashes and check that the gear face
at the end of the crankshaft is smooth.
ks900wD
13-l 66
0
Hammer
If the alignment pin has been removed, knock it in

until it contacts the bottom.
ks9Di ha
Caution: The gear will bend permanently

overheated.
if it is
Never allow the oven tem- A
perature to go above 177 “c.
Heat the crankshaft gear for 45 minutes in an oven

that has already been heated up to 149 “C.
\I I ’ ks9aewc
Coat the tip of the crankshaft thinly with lubricat-

ing oil.
Warning: To prevent injury, always wear protec-

tive gloves.
Install the hot gear up to the crankshaft shoulder

with the timing mark out.
ks9aehd
13-167
0
CAMSHAFT
REPLACEMENT OF CAMSHAFT
AND TAPPET
Preparatory work:
l Remove the valve cover.

l Remove the push rod.
l Remove the drive belt.
l Remove the crankshaft pulley.
l Remove the gear cover.
l Remove the fuel feed pump.
REMOVAL OF CAMSHAFT
Tappet replacement tool (part number 3822513)
Pass a dowel through the hole in the push tube

and insert it securely into the top of the tappet. If it
is installed properly, the dowel can be used to pull
up the tappet. It must not be easy to pull the dowel
out.
Pull upthe tappet and fit a rubber band around the 4~

head of the dowel rod. This will prevent the tap- @@
pet from falling out.
Rotate the crankshaft and align the crankshaft with

the camshaft timing mark.
13-168
0
DISASSEMBLY AND ASSEMBLY CAMSHAFT
13 mm
Remove the mounting bolts from the thrust plate.
Remove the camshaft and thrust plate.
REMOVAL OF TAPPET
I
Insert a trough into the whole length of the cam
bore.
If the wooden dowel has been removed, check that

a trough has been put in position to catch the tap-
pet.
Install one tappet at a time. Leave the rubber band

fitted to the tappets that are not removed. Remove
the rubber band from 2 companion tappets.
I I II
Pull the wooden dowel from the tappet bore and

drop the tappet into the plastic trough.
Flashlight
When the tappet falls into the trough, it will usu-

ally roll out, but if it does not come out, shake the
trough carefully and remove the tappet before re-
moving the trough.
Stoha
Caution: When removing the tappet from the No.

6 cylinder, be extremely careful not to let
the tip of the trough hit or jolt the tappet.
kf9toma
13-170
0
Pull the trough and tappets out carefully from the

cam bore, and remove the tappets. Repeat this
procedure to remove all the tappets.
INSPECTION OF TAPPET
033
Check the socket, stem, and face for excessive wear,
cracks, and other damage.
Visual limit
(A) - normal contact (it is exaggerated)
(B) and (Cl - abnormal contact: do not reuse.
bp9tasa
033
It is possible to use the tappet even if there is a
hollow in the tappet face.
The following standards show the permissible size
of the hollow.
1. A single hollow must not be greater than 2 mm.

2. The tappet cannot be reused if there are con-
nected hollows.
3. The total for multiple hollows must not exceed
$% of the tappet face or a diameter of 6 mm.
4. There must be no hollow at the tip of the tap-
pet wear surface.
Measure the valve tappet stem.
Diameter
mm
15.936 Min
15.977 Max
kf9OOtc
13-171
0
Inspection of camshaft and gear

Inspect the fuel feed pump lobe, valve lobe, and
bearing journal for cracks, hollows or damage.
0
@
cs9shsb
Inspect the camshaft gear teeth for hollows.

Inspect also for cracks at the root of the tooth. 032
Measure the fuel feed pump and valve lobes.
Diameter of lobe at peak

mm
Intake 47.040 Min

47.492 Max
Exhaust 46.770 Min
47.222 Max
Lift pump 35.500 Min
36.260 Max
cg9OOtb
Measure the bearing journal.
Journal diameter
mm
53.962 Min
54.013 Max
13-172
0
&I--NDARDS FOR PIITING WHEN REUS-
The part cannot be reused if there is a single hol-

low of a size greater than the area of a circle of
diameter 2 mm.
The part cannot be reused if the hollows are con-

nected. Treat connected hollows as one hollow.
I ca9OOsd
The total area for all the hollows must not exceed
a circle of diameter 6 mm.
There can be a maximum of only one hollow within

+20” from the nose of the cam lobe.
STANDARD FOR DETERIORATION

(BREAKAGE) OF TIP
Area of deterioration at tip
The area of deterioration at the tip in the area

within _+20” from the nose of the cam lobe must
not be greater than the area of a circle of diameter
2 mm.
The area of deterioration at the tip in the area out-

side +20°from the nose of the cam lobe must not
be greater than the area of a circle of diameter 6
mm.
13-174
0
CAMSHAFT
The first diagram shown below shows the normal polishing pattern and casting flow at the nose. In both
these conditions it is possible to reuse the part. The other three diagrams show wear patterns which do
not permit reuse.
/-@0 -
102El630
13-175
0
102E1631
13-176
0
INSPECTION OF CAMSHAFT BORE

Inspect the camshaft
sive wear.
bore for damage and exces-
0
‘i
Measure the camshaft bore.
Inside diameter
mm
No. 1 bushing 54.146 Max

All except No. 1 54.164 Max
Caution: If the bore without a bushing is worn be-

yond the limit, remove the engine and
carry out machining or install a service
bushing, or replace the cylinder block.
BUSHING
Camshaft bushing tool (part number 3823502)
q
Remove the camshaft bushing from the No. 1 bore.
Make marks on the camshaft bushing and cylinder

block so that the cylinder block oil hole and bush-
ing oil hole can be aligned.
Camshaft bushing tool (part number 3823509)
Install the camshaft bushing so that the front face

of the cylinder block is uniform.
Check that the oil hole is correct.

A rod of diameter 3.2 mm must pass through the
oil hole.
swd
Measure the installed camshaft bushing.
Camshaft bushing bore

mm
54.107 Min
54.146 Max
:89brnb
INSTALLATION OF TAPPET
Insert a plastic trough into the whole length of the
cam bore.
13-178
0
Lower the tappet installation tool to the bushing

tube hole, pass it through the tappet bore and in-
sert it in the trough.
Pull the plastic trough and installation tool out care-

fully from the front, and feed the installation tool
into the cam bore. Generally speaking, the block
at the rear of the trough will pull the tool out.
Add lubricating oil to the tappet.
kf900we
Insert the installation tool in the tappet.
Caution: To make it easier to remove the installa-

tion tool after installing the tappet, insert
and remove the tool from the tappet sev-
eral times before installing the tappet.
Slide the trough into the cam bore.
Pass the tool and tappet through the cam bore then
pull it up into the tappet bore.
If it is difficult to get the tappet to make the bend

from the trough to the tappet bore, put the trough
out so that the tappet can go down and align itself,
then pull the tappet up into the bore.
When the tappet is pulled up to the set position,

slide the trough into the cam bore and rotate it l/2
turns. This will set the rounded side of the trough
at the top and will hold the tappet in the set posi-
tion.
13-180
0
Remove the installing tool from the tappet.
Insert a wooden dowel into the top of the tappet,

then fit a rubber band around the wooden dowel
to hold the tappet in position.
Repeat this procedure to install all the tappets.
kf900wi
q
Coat the front camshaft bore with Lubriplate 105.
Da
Put lubricating oil on the camshaft lobe, journal,

and thrust washer.
ce900wa
13-181
0
install the camshaft. Rotate the camshaft while

pushing in slightly and push the camshaft carefully
through the bushing.
When the camshaft journal passes through the

bushing, the camshaft goes down slightly and the
camshaft lobe holds the bushing. If the camshaft
is rotated, the lobe separates from the bushing and
the camshaft is installed.
II cs900ht
Caution: Do not try to force the camshaft into the

camshaft bore. It will damage the cam- A
shaft bushing.
Before the camshaft gear meshes with the crank-

shaft gear, check that the camshaft rotates easily.
0
@
If it is installed properly, the camshaft will rotate

freely.
Install the thrust washer. Align the timing mark as

shown in the diagram. This completes the instal-
lation of the camshaft.
Install the thrustwasher mounting bolts and tighten

to 24 Nm (2.4 kgm}.
13-182
0
Check that the camshaft clearance and play In tne

axial direction are correct.
A = 0.12 - 0.47 mm
B = 0.76 - 0.33 mm
I
I
I
J
I- A
Install the parts that were removed.
l Gear cover.
l Vibration damper.
l Rocker lever and rocker valve cover.
l Fuel feed pump.
1 - w bP9OOhd
l Run the engine at idling for 5 - 10 minutes

and check for leakage and loose parts. a
0
oi9Olvo
CLEANING OF CAMSHAFT
Clean the camshaft and gear with a cloth and sol-
vent (check that the cloth has no loose threads).
13-l 83
0
INSPECTION OF CAMSHAFT, GEAR

Inspect the lift pump lobe, valve lobe, and bearing
journal for cracks, hollows, or damage.
0
@
co9shsb
0s
Inspect the camshaft gear teeth for hollows. In-
spect also for cracks at the root of the tooth.
ca9srsa
Measure the fuel feed pump lobe and valve lobes.

D
Diameter of lobe at peak
mm
Intake 47.040 Min

47.492 Max
Exhaust 46.770 Min
47.222 MAX
Lift pump 35.500 Min
36.260 Max
cs9OOtb
Measure the bearing journal.
Journal diameter
mm
53.962 Min
54.013 Max
13-184
0
Standards for pitting when reusing cam
The part cannot be reused if the hollows are con-

nected. Treat connected hollows as one hollow.
ce9OOsd
The total area for all the hollows must not exceed
a circle of diameter 6 mm.
There can be only one hollow within +20” from the

nose of the cam lobe. @
13-l 85
0
DISASSEMBLY AND ASSEMBLY CAMSHAFT, CAMSHAFT GEAR
Standards for wear (breakage) when reusing

cam
The area of deterioration at the tip in the area within

+20” from the nose of the cam lobe must not be
greater than the area of a circle of diameter 2 mm.
L’ ce9OOsh
The area of deterioration at the tip in the area out-

side _+20” from the nose of the cam lobe must not
be greater than the area of a circle of diameter 6
mm.
The first diagram shows the normal polish and

casting flaw within the nose portion. Even if both
these conditions exist, it is still possible to reuse
the part.
The other three diagrams show wear patterns
which do not permit reuse.
REPLACEMENT OF CAMSHAFT,
GEAR
When replacing the camshaft gear in a place where
restrictions make it impossible to remove the cam-
shaft from the engine, it is possible to use an in-
staller (795-799-1340). Followthe instructions pro-
vided with the tool.
REMOVAL
Remove the fan pulley.

Remove the crankshaft pulley. For details of the
procedure, see 7-15. q@!
Remove the gear cover. For details of the proce-
dure, see 7-18.
Remove the camshaft. For details of the proce-
bp900mc
dure, see 7-19.
13-l 86
0
DISASSEMBLY AND ASSEMBLY CAMSHAFT GEAR
18 mm
For bolt-on camshafts, remove the camshaft bolt
and washer.
The bolt-on shaft is used only on the 1991 engine
mounting an in-line pump.
ce9boma
Remove the gear.
c%
Q
ce9aeme
Remove the camshaft key.

CE
Q
I ce9kema

Check the camshaft gear visually for cracks, chips,
and broken teeth.
Check the camshaft bore for corrosion and flashes.
Caution: If it is impossible to remove the corrosion,

flashes, or protruding parts with Scotch-
Britd 7449 or equivalent, replace the cam-
shaft gear.
13-187
CAMSHAFT GEAR
0a
Check the camshaft gear key groove for flashes.
Remove the flashes with Scotch-Brite@ 7448 or
eauivalent.
Caution: If the key groove is damaged or the flashes \

GI
cannot be removed, replace the camshaft
gear.
cs9resd
0
Check the camshaft nose visually for corrosion or a
flashes.
Caution: If it is impossible
to remove the corrosion
or flashes with Scotch-Brite@ 7448 or equivalent,
replace the camshaft.
co9OOsj
INSTALLATION
Install the key.
ce9kema
q
Lubricate the camshaft surface with Lubriplate 105
or the equivalent. 4
I ca900nc
13-188
0
DISASSEMBLY AND ASSEMBLY CAMSHAFT GEAR
Caution: The gear will bend permanently

overheated.
if it is
Never allow the oven tem- A
perature to go above 177 “C.
Heat the camshaft gear for non bolted 91 ft cam-

shaft in an over at 149 “C for 45 minutes.
Heat the camshaft gear for non bolted 91 ft cam-

shafts in an over at 145 “C for 45 minutes.
Heat the camshaft gear for bolted 91 ft camshaft
(steel gear) and ail 94 ft automobile to 177 “C.
Warning: To prevent injury from the hot gear, al-

ways wear protective gloves.
a(
Install the camshaft gear with the timing marks
away from the camshaft.
Check that the gear is seated on the camshaft

shoulder. A
Using a 0.001 inch clearance gauge, check if the
clearance gauge can be inserted between the cam-
shaft gear and camshaft gear shoulder. If the clear-
ance gauge can be inserted, the camshaft gear is
not properly seated.
Bolt-on camshaft (1991 engine mounting in-line

pump)
18 mm
Install the camshaft bolt and washer. Tighten the

mounting bolt to 27 Nm 12.8 kgm}, then turn the
mounting bolt a further 180”.
13-189
0
DISASSEMBLY AND ASSEMBLY CAMSHAFT GEAR, REPLACEMENT OF TIMING PIN
install the camshaft.

Install the gear cover.
Install the crankshaft pulley.
Install the fan pulley.
REPLACEMENT
PIN
OF TIMING
q
l/2 inch drive, gear (795-799-11301
@
Push the engine timing pin, carry out barring of
the crankshaft slowly, and set the No. 1 cylinder to
the top dead center (TDC) position.
T-25 Torx
Remove the timing pin assembly and seal.
Install a new seal, and if necessary, install a new 0~

timing pin assembly. Insert pin (A) in hole (B) of @@
the camshaft gear and center the housing.
0K
m: 5 Nm (0.51 kgm}
i t900ve
13-190
0
DISASSEMBLY AND ASSEMBLY REPLACEMENT OF GEAR HOUSING, GASKET
REPLACEMENT OF GEAR
HOUSING, GASKET
REMOVAL
Preparatory work:
Remove the valve cover rocker lever and
push rod. $S@
Remove the vibration damper.
Remove the camshaft.
Remove the fan pump.
10 mm
Remove 6 mounting bolts from the front oil pan.
10 mm
Remove the gear housing mounting bolts. RI
6s
Q
Using a clearance gauge, tryto separate the oil pan

gasket from the gear housing.
I oP9gkrd
13-191
0
Plastic hammer
Remove the gear housing.

Ii-l
Remove the gasket material from the cylinder w
block.
0a
Inspect the oil pan gasket. If it is not worn, coat it
with Three Bond 1207-G sealant.
oD9akwe
REPAIR OF OIL PAN GASKET

r
If the gasket is worn, it may be possible to repair it.
Separate the worn gasket uniformly at the front of
the cylinder block.
oP9gkwf
13-l 92
0
Use the old gasket as the pattern and cut the front
of the new gasket to the same size.
Clean the seal surface, then coat both faces of the

new gasket with Three Bond 1207-G sealant. q
\
oP9skwt
As shown in the diagram, use an extremely thin

wire or normal sewing thread, and secure the new
gasket piece in the set position.
op9akrri
INSTALLATION
Make a 1.59 mm mark on the new gear housing
gasket, then trim it.
Caution: If it is trimmed properly, the gear housing

gasket will be no different from the oil pan
gasket when it is installed.
Put the gasket on the alignment dowel.
10 mm
Install the gear housing carefully and check that

both gaskets are at the set position.
m: 2.4 Nm I2.4 Kgm)
Caution: When installing the new housing or other

parts different from the original housing,
position the timing pin assembly accu-
rately.
Install the oil pan mounting bolts in the holes not

being used for tying the gasket.
Remove the thread or wire holding the gasket.
op9skwl
13-194
0
10 mm
Install the other 2 mounting bolts and tighten to 24

Nm (2.4 Kgm}.
Install the camshaft and thrust washer.
Check that the alignment marks on the

and camshaft gear are aligned.
Install the thrust washer mounting bolts.
m: 24 Nm I2.4 kgm}
Check that the camshaft clearance and play in the

axial direction are correct.
A = 0.12 - 0.47 mm (0.005 - 0.018 in)
B = 0.76 - 0.33 mm (0.003 - 0.013 in}
:
I
I
I
I
L A
I ce9OOnc
Remove the wooden dowel from the tappet.
Install the push rod and add oil.
pr900hd
REPOSITIONING OF TIMING PIN

Caution: When installing the gear housing that was ,_@,
removed, this procedure can be omitted.
Go and complete the installation of the
rocker lever.
Positioning the timing pin assembly in the gear
housing is important for correct adjustment of the
engine. Following this procedure, install the as-
sembly so that it corresponds to the No. 1 cylinder
top dead center (TDC) position.
13-196
0
Make a wire pointer and install it to the front of the

engine. The wire can be held under the gear hous-
ing mounting bolt. Extend the wire to a position
where it can be seen easily from the gear cover to
the crankshaft vibration damper.
Rotate the crankshaft l/4 turn in the normal direc-

tion of rotation of the engine.
Tighten the adjustment screw of the No. 1 intake

valve to zero(O) lash, plus 5 turns.
Caution: Be extremely
crankshaft.
careful when rotating the
If it is rotated with too much A
force, the valve or push rod may be dam-
aged.
Rotate the crankshaft slowly in the reverse direc-

tion to the normal rotation of the engine until the
piston contacts the intake valve.
Make a mark on the vibration damper at the wire
pointer.
13-198
0
Caution: Check that the piston contacts the intake

valve with approximately the same force A
as in the procedure above.
Rotate the crankshaft in the normal direction of the

engine until the piston contacts the intake valve.
Make a mark on the vibration damper at the wire
pointer.
Measure the distance and make a mark on the vi-

bration damper at half the distance between the
two marks. This mark is the TDC position.
Caution: Loosen the adjustment

take valve completely.
screw of the in-
If this is not done,
A
the intake valve or push rod will be dam-
aged when the crankshaft is rotated.
Rotate the crankshaft in the normal direction of

rotation of the engine until the pointer is aligned
with the TDC mark, then rotate one more turn.
The cam gear timing pin hole can be seen or can

be felt through the rear of the gear housing. If it is
not in this condition, rotate the crankshaft one more
turn in the direction of rotation of the engine.
i t9OOvb
Coat the thread of the torx screw with LoctiteTM

59241 and install the timing pin assembly and a
new O-ring.
it9pihc
T-25 Torx
Align with the hole in the housing and insert the litI
timing pin in the hole.
K
0
w: 5 Nm IO.51 kgm1
Install the other rocker lever pedestal assemblies.
13-200
0
IOmm
Tighten the rocker lever pedestal mounting bolts.
For details of the procedure, see 7-03. *
Install the removed components.
l Adjust the valves.

l Injector.
l Fuel injection pump.
l Gear cover.
l Vibration damper.
0s
Run the engine at idling for 5 - 10 minutes and check
for leakage and loose parts.
0
12
9 /;Lf3
L -
GEAR
REMOVAL
Remove the gear.
Remove any flashes made when removing the gear,

and make the rough surface smooth.
I csaoowe
INSTALLATION [SHRINK-FIlTlNG
METHOD)
Install the key. @@
I ca9kema
Add lubricating oil to the camshaft surface.
cQ9oowc
Caution: The gear will bend permanently if it is

overheated. Never allow the oven tem- A
perature to go above 177 “C.
Heat the crankshaft gear for 45 minutes in an oven

that has already been heated up to 149 “C.
Heat bolt-on camshafts gears (steel gears) to 177 “C.
13202
0
Warning: To prevent injury, always wear protec-

tive gloves.
Remove the timing mark from the camshaft and

install the gear.
Check that the gear is seated on the camshaft

shoulder.
If the camshaft is not used immediately,

lobe and journal with oil to prevent rust.
coat the
q
D-
d
INSTALLATION (METHOD USING SPE-

CIAL TOOL)
Installer (795-799-1340)
No. Part Name a’tv

Screw press
Ee
Torque arm
E-Zamer
-a
ca9tosa
Assemble the screw press, yoke, rod, nuts, and

camshaft gear with the chamfered side of the gear
facing the camshaft.
13-203
0
q
Clean the oil and lubricant from the camshaft and \
camshaft gear. Set the yoke on top of the end cam-
shaft bearing journal, then set the gear and tool
assembly in position on the camshaft.
Tighten the screw press and mesh the gear with

the camshaft and key groove.
When the gear is correctly assembled to the cam- 4~

shaft, use the screw press and a wrench, insert the @@
torque arm in the screw press, and install the cam-
shaft gear.
Caution: Do not exceed 135 Nm U3.8 kgm} when

installing the gear. Do not use an impact
wrench togetherwith this tool or any other
Cummins special tool. It may damage the
engine parts or the tool.
I ca9sehd
Turn the screw and gradually increase the force

until the gear is seated on the camshaft shoulder.
When the gear is correctly installed, the gear will
contact the shoulder of the camshaft.
13-204
0
Disassemble the camshaft gear installer, and re-

move the camshaft retainer.
MOUNTING BOLTS
Check that the gear is seated @$*
in front of the cam- ($_
shaft shoulder.
Using a 0.001 inch clearance gauge, check if the A

clearance gauge can be inserted between the cam-
shaft gear and camshaft gear shoulder. If the clear-
ance gauge can be inserted, the camshaft gear is
not properly seated.
Insert the camshaft mounting bolt in the gear re-

tainer, then insert the mounting bolt and retainer Q
C%
assembly to the camshaft.
Tighten the camshaft mounting bolt to 27 Nm (2.8

kgm1. 27N*m[20ft-lb1
13-205
0
REPLACEMENT OF GEAR HOUSING, GASKET
REPLACEMENT OF VIBRATION DAMPER,
DISASSEMBLY AND ASSEMBLY CRANKSHAFT PULLEY
After tightening the camshaft, tighten the mount-

ing bolt a further 180’. @@
REPLACEMENT OF
VIBRATION DAMPER,
CRANKSHAFT PULLEY
REMOVAL
fa9blma
15 mm
Remove crankshaft pulley and vibration damper.

(On the 6-cyl’inder engine, the vibration damper
forms one unit with the crankshaft pulley.)
da9puma
INSPECTION OF RUBBER DAMPER _ ,

Check index line (A) of inertia material (C) and
damper hub (B). If the alignment of both lines is
more than 1.59 mm apart, replace the damper.
Check vibration damper hub (B) for cracks.
If there are any cracks in the hub, replace the
damper.
I da9OOsa
13-206
0
REPLACEMENT OF VIBRATION DAMPER,
DISASSEMBLY AND ASSEMBLY CRANKSHAFT PULLEY
INSTALLATION
Check for deterioration of the rubber. If the rubber
is damaged or missing, or the elastic material is
more than 3.18 mm lower than the metal surface,
replace the damper.
Caution: Check the forward movement of the

damper ring at the hub. If there is any
movement, replace the damper.
\\ da90Osb
Check the mounting web for cracks. Check for

dents or swelling in the surface of the housing. If
such defects are found, replace the damper. See
this section for details of the replacement proce-
dure.
da900sd
Remove the viscous damper. See this section for

details of the replacement procedure.
Clean the damper with detergent.
The viscous damper is filled with silicon liquid.

After many hours of use, the silicon liquid will
become thicker and will expand. When judging if
the damper thickness is correct, remove the paint
from the damper in 4 places on either side of the
damper. Measure the damper thickness at the 4
places and note down the measurement. Measure
the thickness at 3.175 mm from the outside of the
damper. If the thickness varies by more than 0.25
mm, replace the damper.
da900tc
13-207
0
DISASSEMBLY AND ASSEMBLY PISTON, PIN, CONNECTING ROD
REMOVAL OF PISTON
CONNECTING ROD
Align with the cylinder and make match marks on
the connecting rod cap.
Rotate the crankshaft and set so that the piston is

under the carbon deposit at the top of the ring
stroke.
0
a
Use a scraper or a tool without a sharp point to

remove the carbon deposit. Be careful not to
scratch the cylinder with the scraper.
q
\
If any carbon cannot be removed, use a Scotch-

Brite cleaning pad or equivalent to remove the car-
bon.
q
\
13-212
0
DISASSEMBLY AND ASSEMBLY PISTON. PIN. CONNECTING ROD
Warning: Wear protective glasses during this op-

eration and be careful not to get any-
thing in your eyes.
Another way to remove the carbon is to use a drill

with a high-quality steel wire wheel or die grinder.

Do not use a steel wire wheel for the piston stroke.

When removing the deposit with the wheel, move
the wheel in a circle.
Make marks on the piston to match the cylinder.

) c
ca
Caution: In the case of pistons with anodized coat- >
Q 0
ings, do not stamp on the anodized coating or on
the outer rim.
‘> /
Pi9OOsc
12 mm
Remove the mounting bolts, connecting rod cap,

and connecting rod bearing.
Push the connecting rod and piston assembly out

- I
from the cylinder bore. Be careful not to damage

the connecting rod or bearing.
PISTON, PIN, CONNECTING ROD
DISASSEMBLY OF PISTON
CONNECTING ROD
Remove the retaining ring.
I I / cx9r rma
Remove the piston pin.
It is not necessary to heat the piston.
iSDim;
Piston ring tool (795-100-2800)
Remove the piston ring.
CLEANING OF PISTON, PIN,

CONNECTING ROD
Caution: Do not use the bead blast method to clean
the piston. The blasted material will em- A
bed itself in the aluminium and damage
the piston.
Soak the piston in cold detergent.

q
\
Normally, if the piston is soaked for one night, the

carbon deposit can be removed.
13-214
0
Caution: Do not wash the piston and connecting

rod in an acid-proof tank. A
Wash the piston and connecting rod in a solution
of concentrated detergent and hot water. q
\
Oed
Caution: Do not use ring groove detergent. Check

that there is no damage to the ring seal A
surface of the piston groove.
Remove the remaining carbon deposit

pointed end of the damaged ring.
with the q
\
PiSOOee
Wash the piston once more in detergent.

After rinsing it, dry it with compressed air.
\
q
Oed
INSPECTION OF PISTON
Check the piston for damage and excessive wear.
Check the top, ring grooves, skirt, and pin bore.
0s
Caution: If the piston is damaged, check the turbo-
charger and other intake components for
damage from dirt.
PiSOOsb
13-215
0
Piston ring tool (795-100-2800)
The top ring on engines equipped with a turbo-

charger is not the same as the top ring on natu-
rally aspirated engines.
Install the top ring.
pi9OOad
INSTALLATION OF PISTON
CONNECTING ROD a/$
@@
install the bearing shell to both the connecting rod
and connecting rod cap.
Check that the tank at the top of the bearing shell
is fitted inside the cap and connecting rod slot.
cxlbehd
Coat the connecting rod bearing thinly with

Lubriplate 105.
I
cx9bewa
Coat the ring and piston skirt with clean oil.

q4
-
13-220
0
Set the rings in position.
75 - 125 mm ring compressor
Caution: When using a strap type ring compres-

sor, be careful that the tip of the strap on
the inside does not catch in the ring gap
and damage the ring.
Compress the ring with the compressor.
DiStohb
Coat the cylinder bore with clean oil.
Set the connecting rod journal of the piston to be

installed to the bottom dead center (BDC) position.
13-221
0
When inserting the connecting rod, be careful not

to damage the cylinder.
Set the FRONT mark on the piston facing the front

of the cylinder block, and install the piston and
connecting rod assembly in the cylinder bore.
Guide the connecting rod to the crankshaft journal

and push the piston carefully into the bore.
Coat the bottom of the head and thread of the con-

necting rod mounting bolts with oil. 17
e,
cx9cswb
Caution: Align the 4-digit number stamped on the

cap and connecting rod of the parting line
with the engine oil cooler, and install.
Install the connecting rod cap and mounting bolts

to the connecting rod.
13-222
0
Rotate the crankshaft and set 2 connecting rods to

the bottom dead center (BDC) position.
12 mm
Remove the connecting rod mounting bolts and

connecting rod cap.
Remove the lower bearing shell from the connect-

ing rod cap, then mark with the letter L (lower) and
the removed cylinder number.
Push the connecting rod away from the crankshaft

so that the upper bearing shell can be removed.
cx9beme
13-229
0
Remove the upper bearing shell, then mark with

the letter U (upper) and the removed cylinder num-
ber.

Clean the bearing and connecting rod cap, then dry
cx9beec
Check the connecting rod cap, connecting rod bear-

ing saddle, and mounting bolts visually for dam-
age, cracks, flashes, and corrosion.
0a
CX9OOS’
Check the bearing visually for damage.

Replace the bearing if it has any of the following
types of damage.
Holes
Peeling
Corrosion
Damage to lock tongue
Scratches
13-230
0
Check the bearing shell seat surface for scuffing

and flashes. If the scuffing or flashes cannot be
removed with Scotch-Brite@ 7448 or equivalent, re-
place the bearing.
cx9be
Using an outside diameter ball tipped micrometer,

measure the thickness of the connecting rod bear-
ing.
@I
cx9beta
Dimensions of connecting rod bearing

Standard 1.955-1.968 mm
0.25 mm O/S 2.080-2.093 mm
0.50 mm O/S 2.205-2.218 mm
0.75 mm O/S 2.330-2.343 mm
1.00 mm O/S 2.455-2.468 mm
mb8beta
INSTALLATION
Caution: Be sure to install the bearings in the same
position from which they were removed.
Coat the inside diameter of the bearing shell with

Lubriplate 105@ or equivalent.
cx9beab
Insertthe bearing tongue in the connecting rod slot,

and install the upper bearing shell to the connect-
ing rod.
Insert the bearing tongue in the cap slot, and in- 4~

stall the bearing shell to the connecting rod cap.
@@
Coat the inside diameter of the bearing shell with
Lubriplate 105@ or equivalent.
cx9behf
Coat the thread and bottom of the head of the con-

netting rod mounting bolts with clean 15W-40 oil.
Align the 4-digit number stamped on the connect-

ing rod cap at the parting line with the engine oil
cooler, and install.
Install the connecting rod cap and mounting bolts
to the connecting rod.
13-232
0
DISASSEMBLY AND ASSEMBLY BALANCER
13 mm
Remove the thrust housing.
ba900fa
8 mm hexagon wrench
Remove the idler gear assembly.
ba9sema
13 mm
Remove the balancer weight.
Push the shaft out from the gear.
II ba9bemb
13-242
0
Remove the shaft from the balancer housing.
ba9shma
3/16 inch punch, hammer
Using the punch, knock the roll pin out from the
shaft.
ba9doma
Remove the woodruff key from the shaft.

@@
ba9kema
Push the shaft out from the thrust collar.
13-243
0
Push the shaft out from the bearing inner race.
ba9bema
Push the bearing out from the balancer housing.
ASSEMBLY
The center bearing oil hole must be aligned with
the oil hole in the housing.
To make it possible to align the holes, make marks
1. ba9bemb
on the housing and bearing.
ba9bewa
Caution: Push the end of the bearing marked with

the distinguishing mark. If this is not
done, the bearing will be damaged.
Push the new center bearing in until it is level with

the housing.
ba9beha
13-24
0
Install the bearing to the housing so that the dis-

tinguishing mark faces the outside of the housing.
ba9behb
Caution: Push the end of the bearing marked with

the distinguishing mark. If this is not
done, the bearing will be damaged.
Push the new bearing in until it is level with the

inside of the housing.
ba9beda
Assemble the balancer shaft before installing it to

the housing. The assembly procedure is the same
for both shafts.
Polish the bearing surface with 500 grit sandpaper

to remove the flashes and Loctite.
Use detergent to clean the surface of the shaft and q
\
bearing.
ba9shwa
Hammer or mallet
Install a new roll pin to one of the holes in the cen-

ter of the shaft.
A = 2.5 mm
m
.____!
0 0
ba9doha
13-245
0
Coat the shaft bearing surface with LT-4. Slide the @Jb
new inner race to the specified position on the shaft. @@
\
liiiii2
c
ba9behc
Remove any excess LT-4 from the shaft.

q
ba9bewb
Install the remaining three roll pins.
A = 2.5 mm
I ba9dohb
Coat the bearing surface with LT-4.
-2 0
bailshwb
13-246
0
Slide two new inner races to the end of the shaft.

Set the distinguishing mark facing the end of the
shaft.
ba9beaa
Remove any excess LT-4.

\
q
bagshea
Push the thrust collar to the stepped portion of the

shaft.
I I
ba9srha
Install the woodruff key to the shaft.
ba9kema
13-247
0
Coatthe thrust plate with Lubriplate. Set the thrust

plate to the housing.
Add clean oil to the bearing. Install the bottom

shaft to the housing. There is a timing pin hole in
the bottom shaft.
Caution: There is a tappet type hole for the timing

pin on the shaft of later models. On the
original shaft, there is a hole for the tim-
ing pin bored through the shaft.
Push the gear with one timing mark against the

bottom shaft until the gear is level with the end of
the shaft.
ba9aeha
Add clean oil to the bearing and install the top shaft.
13-248
0
Caution: When pushing the gear on to the shaft,

align the timing mark.
Press fit the gear with two timing marks until the
gear is level with the end of the shaft.
balaehb
13 mm
Coat the thrust housing with Lubriplate. Install the

thrust housing. Align the position of only one of
the mounting holes.
w: 24 Nm I2.4 kgm}
Use clean oil. I,

Add oil to the new bearing, then install it to the m
idler gear assembly.
bagbehd
Align the holes of the idler

ment pin and the housing.
bagaehc
13-249
0
Plastic mallet
Tap the idler gear assembly in carefully to the speci-

fied position.
Install 2 hexagonal mounting bolts to the idler as-

sembly. Tighten the mounting bolts by hand.
ba9sehe
8 mm hexagon wrench
Install the balancer weight to the shaft. Install the

weight to the counterbore side of the hole.
w: 24 Nm I2.4 kgml
Check that the balancer assembly rotates freely. If

it does not rotate freely, check if the thrust housing
and bearing are installed properly.
I ba9sedt
13-250
0
DISASSEMBLY AND ASSEMBLY GEAR COVER
GEAR COVER
REPLACEMENT OF GEAR COVER
REMOVAL
6s
Q
fa9blmi
15 mm
Remove the crankshaft pulley. RI

c%
Q
da9puma
10 mm
If necessary, remove the hub pulley.
fa9puoa
10 mm
Remove the front gear cover.
13-251
0
GEAR COVER

Clean the gear cover and gear housing gaske \
t sur- u
face.
Check the gear cover for cracks or damage.
ac900sa
Caution: Before installing the gear cover

, clean and
dry the crankshaft, and remove all oil and
grease. If the seal surface is not properly
A
cleaned, it will cause oil leakage.
INSTALLATION
Install a new seal to the gear cover.
gc9sehc
13-252
0
_. _
Coat only the cover side of the front cover gasket
thinly with a bead of Three Bond.
Caution: At this point, do not remove the plastic

seal pilot tool from the oil seal. Using the
plastic seal pilot tool, guide the seal on to
the crankshaft.
Tighten the front cover mounting bolts. . -.

Remove the plastic seal pilot tool from the crank- 6 -.
RI
I
0(K 0
4
0 0
shaft. -- -
0
O6
m: 24 Nm 12.4 kgm)
0 0
I/ $
/_4
6
I
I sc9tamb
15 mm
Install the crankshaft pulley. At this point, do not

tighten the mounting bolts to the specified torque.
da9puma
Install the drive belt.
fa9blma
13-253
0
Tighten the crankshaft pulley mounting bolts.
w: 125 Nm I12.7 kgm1
INSTALLATION OF GEAR COVER

Lubricate the front gear train with clean oil.
Ll
Da
Caution: If the seal lip and crankshaft seal surface

are not dry and completely free of oil, it
will cause oil leakage.
Clean the crankshaft front seal mounting surface.
Caution: When removing and installing the gear

cover, always replace the front seal.
10 mm
Coat only the front cover side of the gasket thinly

with Three Bond.
Caution: At this point, do not remove the plastic

seal pilot tool from the oil seal. Using the
plastic seal pilot tool, guide the seal on to
the crankshaft.
Install the gasket and front cover.
\ / ! / ec9hshb
13-254
0
Tighten the front cover mounting bolts.

Remove the pilot from the crankshaft.
I0 0 6--
,6-
w: 24 Nm I2.4 kgm} --0-
O6
0 0 0
@
3 J
/5
6
I ec9tomb
Install the front cover access cap and seal.
sc900hb
15 mm
Install the crankshaft pulley or vibration damper.

At this point, tighten the mounting bolts partially.
dallpuma
l/2 inch square head drive
Raise the belt tensioner and install the belt.
fa9blma
13-255
0
15 mm
Tighten the crankshaft pulley.
m: 125 Nm I12.7 kgm1
da9puha
INSPECTION OF GEAR HOUSING AND

TIMING PIN
0a
Check the gear housing visually for cracks or dam-
age.
Check the seal surface.
sc9OOsb
0
Check the timing pin housing and pin for damage. a
t3
it9pisa
DISASSEMBLY OF GEAR HOUSING

If there is no damage or leakage, or the gear hous-
ing is not replaced, do not remove the timing pin
housing.
i t9hsba
13-256
0
Caution: If the rivets are knocked in too far, they

will tear through the data plate.
A
aP9OOba
2.0 mm drill bit
If the data plate is loose or damaged, make new

holes and install with new rivets. Make a mark at &j~
the 6.0 mm point on the drill bit to make sure that @
@
the hole is not too deep.
s
i4
aP9OOxa
6
Be careful not to damage the data printed on the

plate when making the holes in the data plate.
Knock in until the rivets contact the data plate.
aP9OOhc
13-258
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD
13
13
4
a
4/
‘!
kn900am
13-260
0
Index No. Part Name QW Remarks
1 Dowel ring 1 Standard only

2 Cylinder head 1
3 cup Plug 3 13/16 in.
4 Fuel filter insert 1 Standard only
5 Pipe plug 4 l/2 in. NPTF
6 Pipe plug 2 l/8 in. NPTF
7 Intake valve 4
8 Exhaust valve 4
9 Valve seal 8
10 Valve spring 8
11 Valve spring retainer 8
12 Valve half collet 16
14 Hexagonal mounting bolt 4 M12-1.75 x 120
15 Cylinder head gasket 1 M12-1.75 x 70
13-261
0
OUTLINE
The cylinder head has 2 valves installed to each
cylinder and has a l-piece cross-flow design. The
features of the cylinder head are that it is fully
equipped type with cast valve guides, induction
hardened seatsurface, integrated intake manifold,
fuel filter head, and thermostat housing.
On the high-output 6-cylinder engine equipped

with in-line fuel injection pump, the fuel filter head
has been removed to give a larger clearance for
the fuel injection pump. The injectors are installed
to the cylinder head, so they can carry out direct
injection into the cylinder.
The cylinder head gasket forms a composite de-

sign with the fire ring which seals the cylinder bore.
The gasket orifices control the flow of the cooling
water.
The valve seat can be ground once. If a valve seat

has already been ground, it is possible to replace
it with a service valve seat. A service valve guide
can also be used when replacing a worn guide.
13-262
0
CYLINDER HEAD
REPLACEMENT OF CYLINDER HEAD

REMOVAL
Preparatory work:
l Drain the coolant.
. Remove the coolant and heater hoses.
Remove the turbocharger and exhaust manifold.
Remove the injectors and fuel line.
Remove the rocker lever and push tube.
13-263
0
IOmm
•l
Remove the intake manifold cover and intake heater
(when installed).
When installing, be sure that the manifold cover is C% Q
facing in the correct direction.
318 inch square drive

El
6%
Q
fa9blma
13 mm
Remove the belt tensioner.
5 mm hexagon wrench
Remove the belt tensioner bracket.
13-264
0
IOmm
Remove the fan hub assembly.
Caution: If the fan bracket is not connected to the

cylinder head, this step can be omitted.
fa900md
10 mm
Loosen the alternator link, mounting bolts, and •l

mounting bolts of the coolant inlet port connec-
tion.
Remove the alternator bracket mounting bolts and
rotate the alternator to move it away from the en-
gine.
10 mm
Remove the thermostat housing assembly.
fh9hsma
18 mm
Remove the cylinder mounting bolts in the order

13-265
0
Remove the cylinder head and gasket from the cyl-

inder block. Q
GS
4-cylinder: 36 kg
6-cylinder: 51.3 kg
Caution: Inspect the cooling water passage. If there

is rust and scale accumulated, remove the
cylinder block for cleaning in the hot tank.
kn9bdmb
Straight edge and clearance gauge
Using a straight edge and clearance gauge, mea- •l

sure the total flatness of the cylinder block.
The total flatness both along the length and across
width must not exceed 0.075 mm.

033
For details of the procedure and limitations for @
regrinding and milling, see the replacement repair ck9OOtd
manual.
INSPECTION BEFORE DISASSEMBLY OF

CYLINDER HEAD
q
Clean the cylinder head with detergent.
\
Check visually for damage which makes it impos-

sible to reuse the cylinder head. Check for dam-
age and cracks in the deck surface that will cause
loss of sealing.
13-266
0
DISASSEMBLY OF CYLINDER HEAD

The following procedure for disassembly and as-
sembly is only for the purpose of inspection. For
details of the procedure for reassembly, see Bulle-
tin.
Make marks on the valves to distinguish the posi-

tion.
Compress the valve spring and remove the valve

stem collet.
Remove the collet.
kn9ctmb
Remove the valve spring; then remove the retainer

spring.
I kn9spmc
Remove the remaining collet, retainer, spring, and

valve.
When measuring, keep the valves on the labeled
rack for a correct match with companion seats.
c%
Q
13-267
0
Remove the valve stem seal.
c%
Q
w kn9shma
CLEANING OF CYLINDER HEAD

Brush (795-799-I 140)
Remove the carbon from the injector nozzle seat.
Remove
face.
the gasket material from the gasket sur-
\
q
x&s_ n-
--i-b-- o-0 -r\
- --&
\
Clean the accumulated deposits from the cooling

water passage. If there is a thick deposit, the parts
can be washed in acid-proof tank, but first, remove
the cup plug.
13-268
0
Using a Scotch-Brite pad or equivalent cleaning pad

and diesel fuel or detergent, wash the combustion
deck of the cylinder head.
kn9bdeg
Caution: Wear protective glasses.
Install a high-quality steel wire wheel to a drill or

Al Hi I
die grinder and remove the carbon deposit from \
the valve pocket. cl

Wash the cylinder head with hot soapy solution. \

Wash the cylinder head in hot soapy water solu- A
tion, then dry with compressed air.
kn9bdeh
Warning: Wear protective glasses.

A
Clean the valve head with a soft wire wheel.
Before starting the measuring operation, put the
valves on a labeled rack and be careful not to mix
\
q
the valves.
kn9vaea
13-269
0
q
Using a Scotch-Brite pad or equivalent cleaning pad \
and diesel fuel or detergent, polish the valve stem.
kn9vaeb
INSPECTION OF VALVE
Check the head and stem for abnormal wear.
032
kn9vaac
Measure the diameter of the valve stem.
Valve stem diameter

mm
7.94 Min
7.98 Max
kn9vata
Check the flatness of the tip of the valve stem.

a
kn9vasd
13-270
0
Check the curvature of the valve visually.

@/
kn9vase
Measure the thickness of the rim and judge if there

is room to polish the valve.
Limit
Min (thickness TI: 0.79 mm
If it is judged that the valve surface can be ground.
kn9vatc
INSPECTION OF VALVE GUIDE

Check the valve guide for damage.
Measure the valve guide bore.
Valve guide bore diameter

mm
8.019 Min
8.090 Max
If inspection shows.that the valve guide is dam-

aged, see replacement repair manual for details.
kn9sunb
I-
INSPECTION OF CYLINDER DECK

Using a straight edge and clearance gauge, mea-
sure the total flatness of the cylinder head deck.
The flatness across the width must not exceed 0.075
mm. The flatness along the length must not ex-
ceed 0.203 mm on the 4-cylinder engine; it must
not exceed 0.305 mm on the 6-cylinder engine.
For details of the procedure and limitations for
regrinding and milling, see the replacement repair
manual. I kn9OOtb
I
13-271
0
INSPECTION OF VALVE SEAT

Check the valve seat for cracks or signs of burning.
If there are any cracks, refer to the following stan-
dards for reuse. If it is necessary to grind more
than 0.254 mm to finish the seat smooth, it is pos-
sible to use a service valve seat. For details of the
procedure for installing the valve seat, see replace-
ment repair manual.
kn9OOkm
STANDARDS FOR CRACKS IN CYLINDER

HEAD WHEN REUSING
These standards apply only when the crack extends
from the injector bore to the intake valve seat. If
there are cracks in the valve bridge in any other
place, replace the cylinder head.
kn9OOkn
The standards for reuse when the crack extends

from the injector bore to the intake valve seat are
as follows.
If the crack does not enter the valve seat, it is pos-
sible to reuse the cylinder head.
kn900kl
If the crack extends into the valve seat or passes

through it, install a valve seat insert to repair the
cylinder head. For details, see replacement repair
manual.
13-272
0
Valve spring compressor
After assembling the spring and retainer, compress

the valve spring.
kn9sphd
Plastic hammer
Caution: Wear protective glasses. If the collet is

not installed properly, it may fly off when
the stem is hit with a hammer. A
After assembling, tap thevalve stem with the plas-
tic hammer to check that the collet is correctly
seated.
kn9vaw
INSTALLATION OF CYLINDER HEAD

Caution: Check that the gasket is aligned with the
cylinder head holes.
A
Set the cylinder head gasket on the dowels.
13-274
0
Set the cylinder head carefully on top of the cylin- @JB

der block and seat it on the dowels.
@@
&I kg 4-cylinder engine - 36 kg
& kg 6-cylinder engine - 51.3 kg

Install the push rod to the valve tappet.
PrSOOhe
Add engine oil to the push rod socket.

u4
INSTALLATION OF ROCKER LEVER

Add oil to the valve stem.
13-275
0
Completely loosen the rocker lever adjustment

screw.
r h9sswa
Caution: Align the rocker lever pedestal with the

dowel.
Install the pedestal.
Using the service tool (Part No. 3823921), install

the cylinder head mounting
length.
bolts to the correct 032
Add engine oil to the thread of the 8 mm pedestal
mounting bolts and the bottom of the head of the
qe,
mounting bolts.
Install the mounting bolts and tighten by hand. e

Add engine oil to the thread of the 12 mm pedes- IT b
tal/head mounting bolts and the bottom of the head
of the mounting bolts.
rh9cswb
13-276
0
Lubricate the threads and under the heads on the

remaining cylinder head mounting bolts with en-
gine lubricating.
Tighten the cylinder head mounting bolts in the

kr l9csma
18 mm
Step Tightening torque value
1. Tighten all mounting 90 Nm I 9.2 kgm1

bolts.
2. Check 90 Nm 1 9.2 kgm}
3. Tighten long mounting 120 Nm (12.2 kgm1
bolts only
4. Check long mounting 120 Nm 112.2 kgm)
bolts
5. Tighten all mounting bolts a further 90”
kn9csod
13 mm
Tighten the 8 mm pedestal mounting bolts.
w: 24 Nm I2.4 kgm}
rh9csoa
13-277
0
ADJUSTING VALVE CLEARANCE

Adjust the valve clearance.
IO mm
Install the manifold cover plate, fuel filter head, and
intake air heater.
Secure the cover plate with the mounting bolts as
Using the other holes, secure the fuel line bracket.
m: 24 Nm I2.4 kgm}
im9cvmh
Install the injector and fuel line.

63
Q
Install the exhaust manifold and turbocharger.

4
CE
@
tb9OOhc
13-278
0
INSTALLATION OF BELT TENSIONER

5 mm hexagon wrench
install the tensioner bracket to the cylinder head.

Tighten the socket head screws.
w: 24 Nm I2.4 kgm}
13 mm
Install the belt tensioner to the bracket and secure

with the mounting bolts.
m: 43 Nm I4.4 kgm}
Caution: There are some tensioners that can be

installed by bolt to 2 places on the bracket.
Install to the more convenient position.
INSTALLATION OF ALTERNATOR
IO mm
Assemble the alternator bracket to the thermostat

housing.
w: 24 Nm I2.4 kgm}
eh9braa
Checkthe alternator pulley visually or use a straight

edge to check if the center is aligned with the other
pulleys and that it is parallel to the front face of the
block.
13-280
0
Tighten the mounting bolts in the following order.
1. Alternator bracket mounting bolts for alter-

nator
2. Alternator mounting bolts for bottom brace
3. Cooling water inlet port mounting bolts for
alternator
4. Block mounting bolts for cooling water inlet
Port
Caution: The size of the wrench and the torque
value depend on the alternator manufac-
turer and the model. For details of the
torque value, see Engine Components.
INSTALLATION OF DRIVE BELT

Raise the tensioner and install the belt.
Operating hint:
If it is difficult to install the drive belt (the belt may

be too short), fit the belt on the grooved pulley and
raise the tensioner while sliding the belt over the
water pump pulley.
fa9bIma
INSPECTION BEFORE DISASSEMBLY

Wash the cylinder head with detergent.
q
\
kn9bdee
0a
Check visually for damage which makes it impos-
sible to reuse the cylinder head. Check for dam-
age and cracks in the combustion surface that will
cause loss of sealing.
13-281
0
DISASSEMBLY OF CYLINDER HEAD

Make marks on the valves to distinguish the posi-
tion.
Compress the valve spring and remove the valve

stem collet.
Remove the valve spring, then remove the retainer

and spring.
I kn9sPmc
Remove the other collets, retainers, springs, and

va Ives.
When measuring, keep the valves on the labeled

rack in sets with their companion seat.
kn9vamb
13-282
0
Remove the valve stem seal.
kn9shma
CLEANING OF CYLINDER HEAD

Brush (795-799-l 140)
Remove the carbon from the injector nozzle seat.
liil
f i9bref
Remove the gasket material from the gasket sur-

face.
kn9okea
Clean the accumulated deposits from the cooling

water passage. If there is a thick deposit, the parts
\
q
can be washed in acid-proof tank, but first, remove
the cup plug. For details of the procedure for re-
placement of the cup plug.
I kn9bdef
13-283
0
Using a Scotch-Brite pad or equivalent cleaning pad

and diesel fuel or detergent, wash the combustion
deck of the cylinder head.
“C..L..__ ’
kn9bdes
Caution: Wear protective glasses.

A
Install a high-quality steel wire wheel to a drill or
die grinder and remove the carbon deposit from
the valve pocket.
\
q
- IL--I !I
kn9bree
Wash the cylinder head with hot soapy solution.

Rinse the cylinder head, then dry with compressed
\
q
air.
kn9bdeh
Warning: Wear protective glasses.

A
Clean the valve head with a soft wire wheel.
Before starting the measuring operation, put the \

q
valves on a labeled rack and be careful not to mix
the valves.
kn9vaea
13-284
0
Using a Scotch-Brite pad or equivalentcleaning pad

and diesel fuel or detergent, polish the valve stem.
\
q
kn9vaeb
INSPECTION OF VALVE
Check the head and stem for abnormal wear.
kn9vasc
Measure the diameter of the valve stem.
Valve stem diameter

mm
7.94 Min
7.98 Max
kn9vata
Check the flatness of the tip of the valve stem.
I kn9vasd
13-285
0
04s
Check the curvature of the valve visually.
kn9vase
Measure the thickness of the rim and judge if there

is room to polish the valve.
Limit
Min (thickness T): 0.79 mm
If it is judged that the valve surface can be

ground, see page 2-13 for details of the
grinding procedure.
kn9vatc
INSPECTION OF VALVE GUIDE

Check the valve guide for scratches or other dam-
age.
Valve guide bore diameter

mm
8.019 Min
8.090 Max
If inspection shows that the valve guide is dam-
aged, see replacement repair manual.
kn9aunb
INSPECTION OF CYLINDER HEAD COM-

BUSTION DECK
Check visually for any abnormality in the cylinder
head combustion surface (hollows, grooves, sink-
ing of fire ring, etc.).
If there is any problem, grind the cylinder head
deck. For details of the procedure, see replacement
repair manual.
13-286
0
Measure the flatness of the total cylinder head.
End-to-end: 0.305 mm (6B)

Side-to-side: 0.203 mm (4B)

INSPECTION OF VALVE SEAT

Check the valve seat for cracks or signs of burning.
If there are any cracks, refer to the following stan-
dards for reuse. If it is necessary to grind more
than 0.254 mm to finish the seat smooth, it is pos-
sible to use a service valve seat. For details of the
procedure for installing the valve seat, see Bulle-
tin No. 3810234 replacement repair manual.
kn900kn
STANDARDS FOR CRACKS IN CYLINDER

HEAD WHEN REUSING @I
These standards apply only when the crack extends
from the injector bore to the intake valve seat. If
there are cracks in the valve bridge in any other
place, replace the cylinder head.
kn9OOkn
-
0a
The standards for reuse when the crack extends
from the injector bore to the intake valve seat are
as follows.
If the crack does not extend into the valve seat, it is
possible to reuse the cylinder head.
kn9OOko
13-287
0
400 grit sandpaper, diesel fuel
Clean the cup plug hole.
I kn9boea
A
Caution: Wear protective clothes to prevent injury.
Inspect the water cooling passage for deposited

sediment.
If there is any deposit, it will cause overheating of 032
the engine.
Check that the water passage is clean. If there is \
excessive sediment, it can be washed out in an acid-
proof tank, but disassemble the cylinder head be-
q
fore this.
Caution: Wear protective clothes to prevent injury.
Put hot soapy water in a tank and wash the cylin-

A
der head.
kn9bdeh
Caution: Before installing the cup plug, wash the

cup plug and cup plug hole and remove
any oil.
Before installing, coat the outside circumference

of the cup plug with LT-4.
kn9epwa
13-289
0
CYLINDER HEAD
Cup plug driver (6732-21-1830)
Push in the cup plug until the outside edge is level

with the counterbore.
Position of cup plug
1. 13/16 inch
POLISHING VALVE
Polish the whole surface of any valve that is to be
reused. Check or replace the vent valve.
Limit of seat
Intake: 30’
Exhaust: 45”
13-290
0
Measure the rim thickness.
Valve rim thickness

Min (thickness T): 0.79 mm
I kn9vatr
Inspect the flatness of the tip of the valve stem.
kn9vasd
If necessary, polish the surface of the tip.
POLISHING VALVE SEAT

If there is any mark as shown in the diagram, it
means that the valve seat has already been ground
before. If it is ground again, further grinding will
cut into the induction hardened surface.
Replace any seat that has already been ground, and
use a service seat. For details, see replacement
repair manual.
13-291
0
CALCULATING GRINDING DEPTH AND

MEASURING DEPTH OF VALVE
Depth gauge (295-290-1300)
Install the valve in the specified position and mea-

sure the valve depth.
kntlvana
There are two important parameters for the valve e _

seat when grinding the valve.
The first is to match the limit for the valve depth,
and the second is to observe the limit for the grind-
ing depth, and to make sure that the grinding does
not penetrate the hardened layer of the valve seat.
If these two parameters do not match the specifi-
cations, see Bulletin No. 3810234 replacement re-
pair manual.
kn9vanh
The valve depth is the distance from the valve face

to the head deck.
Note down depth (A) for each valve.
Valve depth
mm
0.99 Min
1.52 Max
If the valve depth does not match the specifications,

replace the valve seat.
042
If the valve meets the standard for the initial valve
depth, grind the valve seat to remove any chips,
scratches, burns, or other damage.
13-292
0
Limit for seat
Intake: 30’
Exhaust: 45’
ranj
Depth gauge (295-290-1300)
After grinding the seat, measure the valve depth

again and calculate the grinding depth.
q
m
Install each valve into the bore and measure the

depth. Note down depth (8) for each valve.
Always clean the seat before measuring the depth.
Calculate the grinding depth (GD) as follows.
GD = (B) - (A)
Limit for grinding depth of seat
GD: 0.254 mm
If the seat exceeds the limit, it is possible to
use a service valve seat.
Check that valve depth (B) after grinding is still

within the original specification.
Valve depth (Al or (Bl

mm
0.99 Max
1.52 Min
kn9vano
13-293
0
To distinguish the valve seat after grinding, make

an (X) mark on the cylinder head.
Coat the valve lightly with valve lapping compound

and lap the valve with the compound.
Remove the valve and clean the lapping compound

from the valve and seat.
kn9vaec
Seat the valve in the center of the valve face.

Measure the width of the valve seat at the lapped
surface.
Valve seat width limit

mm
1.5 Min. (I)

2.0 Max. (2)
kn9vanm
13-294
0
r
To make the seat come in the center of the valve
face, grind portion (A) with a grind stone to 60’
and portion (B) to 15’to bring the valve seat width
within the limit.
Limit of valve seat width

mm
1.5 Min
2.0 Max
kn9vano
The key to determining the grinding angle is the

lapped surface of the valve face. If the lapped sur-
face is at the bottom of the valve face, it will be
necessary to grind more of the seat at 60” than at
15”.
If the lapped surface is at the top of the valve face,

it will be necessary to grind more of the seat at 15”
than at 60”.
kn9vate
When the seat fits in the center of the valve face,

coat the valve face with steel blue and dry it.
kn9vaws
13-295
0
Coat the valve with valve lapping compound and

lap the valve with its companion seat.
Remove the valve, and clean off the lapping com-

pound from the valve face and seat.
Check the center and width of the valve face.
Width of valve seat

mm
1.5 Min
2.0 Max
kn9vct I
ASSEMBLY OF CYLINDER HEAD

Caution: Clean the cylinder
fore assembling.
head components be-
q
\
Install the valve stem seal. q$

Use the same parts for the intake and exhaust seal. &@
kn9seha
13-296
0
Before installing the valve, add engine oil to the

stem. 0,
c
Valve spring compressor
After assembling the spring and retainer, compress

the valve spring.
kn9sphd
Install a new valve collet and apply tension to the

spring.
Plastic hammer
Caution: Wear protective glasses. If the collet is

not installed properly, it may fly off when
the stem is hit with a hammer.
After assembling, tap the valve stem with the plas-

tic hammer to check that the collet is correctly
seated.
kn9vawd
13-297
0
673501
DISASSEMBLY AND ASSEMBLY ROCKER LEVER
Index No. Part Name Remarks
1 Rocker lever support 4

2 cup plug 8
3 Rocker lever (intake) 4
4 Grooved set screw 4 3/8 inch - 24 UNF-2A
5 Normal hexagonal nut 4
6 Rocker lever (exhaust) 4
7 Plain washer 8
8 Retaining ring 8
9 Hexagonal mounting bolt 4 M8 - 1.25 x 75 mm
10 Hexagonal mounting bolt 4 Ml2 - 1.75 x 180 mm
11 Push rod 8
13-299
0
OUTLINE
There is a separate rocker lever assembly for each
cylinder of the engine. Each assembly consists of
an intake rocker lever, exhaust rocker lever, rocker
lever shaft, and pedestal support. There is a hole
in the pedestal support to send oil to the shaft and
lever.
The lever is moved by the push rod, and an ad-

justment screw is used to control the clearance
between the lever and valve stem. The lever does
not use a bushing in the rocker lever shaft. If the
lever exceeds the limit for wear or damage, re-
place it.
13-300
0
REPLACEMENT OF ROCKER LE-

VER AND PUSH ROD
REMOVAL
15 mm
Remove the valve cover.
14 mm
Loosen the locknut of the adjustment screw. Exl

Loosen the adjustment screw until it stops.
13 mm, 18 mm
Remove the mounting bolts from the rocker lever

pedestal. Remove the pedestal and rocker lever
assembly.
Remove the push rod.

ROCKER LEVER
DISASSEMBLY OF ROCKER LEVER

I
When inspecting the rocker lever and push rod to
judge if they can be used again, do as follows.
Remove the retaining ring and thrust washer.
rh9rrma
Remove the rocker lever.
rh9lvma
Caution: Do not disassemble the rocker lever shaft

and pedestal. Replace the pedestal and A
shaft as an assembly.
rh9shbc
Remove the locknut and adjustment screw.
rh9numa
13-302
0
CLEANING OF ROCKER LEVER I -
q
Make a concentrated solution of detergent and hot 1
water, and wash the parts.
Rinse in clean hot water, then dry with compressed

air. q
\
Caution: The pedestal is made of metal powder,

so even if it is dried after washing, it will
remain damp for some time.
INSPECTION OF ROCKER LEVER
035
Check the valve stem bore and contact surface for
cracks or excessive wear.
rh9bdsa
Measure the rocker lever bore.
Limit
Diameter (max): 19.05 mm
rh9brta
Check the pedestal and shaft.

Measure the diameter of the shaft.
Limit
Min. diameter: 18.94 mm
rh9shta
ASSEMBLY OF ROCKER LEVER

Install the adjustment screw and locknut.
rh9numa
Caution: Check that the intake and exhaust side

rocker levers are assembled to the cor- A
rect place.
0
cl
~~~
0
Intake Exhaust
rh9lvba
Add engine oil to the shaft.
rh9shwc
13-304
0
Install the levers to the rocker shaft.
Install the thrust washers.
rh9waha
Snap ring pliers

Install the snap springs.
rh9rrha
INSTALLATION OF ROCKER LEVER

I
Check that the pedestal dowel ring is installed in
the dowel bore.
0a
Using the service tool (Part No. 38239211, check if
the cylinder head mounting bolts are the correct
length.
Coat the thread and bottom of the mounting bolt O-,
head with clean engine oil. tl
Install the mounting bolts to the pedestal.
rh9cswa
18 mm
Step 1: All tighten cylinder head mounting bolts to

90 Nm 19.2 kgm}.
RI
Step 2: Tighten only the long cylinder head mount-
0 ($
ing bolts to 120 Nm (12.2 kgm).
18 mm
Step3: After tightening the long cylinder head

mounting bolts to 120 Nm (12.2 kgm1,
tighten all the mounting bolts a further 90”.
13 mm
Tighten the 8 mm pedestal mounting bolts.
w: 24 Nm Q.4 kgm1
0T
rh9csnc
13-306
0
DISASSEMBLY OF ROCKER LEVER

Snap ring pliers
Remove the retaining ring and thrust washer.
c%
Q
rhlrrma
Remove the rocker lever.
rh9lvma
Replace the pedestal and shaft as an assembly. Do

not disassemble. A
rh9shba
Remove the locknut and adjustment screw.
rh9numa
CLEANING OF ROCKER LEVER, ROCKER

LEVER SHAFT
Make a concentrated solution of detergent and hot
water, and wash the parts.
Rinse in clean hot water, then dry with compressed

air.
Caution: The pedestal is made of metal powder,

so even if it is dried after washing, it will
remain damp for some time.

Check the valve stem contact surface and bore for
cracks or excessive wear.
rh9bdsa
Measure the rocker lever bore.
Diameter
mm
19.000 Min
19.051 Max
rh9brta
13-308
0
DISASSEMBLY AND ASSEMBLY ROCKER LEVER ASSEMBLY

SHAFT
Check the pedestal and shaft for damage.
Diameter
mm
18.938 Min
18.975 Max
rh9shta
ASSEMBLY OF ROCKER LEVER

Install the adjustment screw and locknut.
rh9numa
Add engine oil to the shaft.
rh9shwc
Install the levers to the rocker shaft.
rhllvma
ROCKER LEVER
Check that the intake and exhaust side rocker le-

vers are assembled to the correct place.
Intake Exhaust
rh9lvba
Install the thrust washers.
I rh9waha
Snap ring pliers
Install the snap springs.
rhllrrha
13-310
0
DISASSEMBLY AND ASSEMBLY TAPPETS AND PUSH RODS
TAPPETS AND PUSH RODS

kf900ab
13-311
0
OUTLINE
t
I
n I
The camshaft is equipped with a lobe to move the
intake and exhaust valves and a special lobe to
&;k-
drive the lift pump. The valve lobe lifts up the push
rod, opens the valve, and contacts the valve tap-
pet.
‘- ’
The tappet is a mushroom shape, and is installed
so that the center line of the tappet is offset from
the center line of the cam lobe. Because of this
offset, the tappet rotates and lifts up the push rod.
I
cs900sa
The ball end of the push rod fits into the ball socket
of the tappet. The other end is fitted with a ball
socket which moves the ball end of the rocker le-
ver adjustment screw.
pr900sa
13-312
0
CLEANING OF PUSH ROD

Wash the push rods in soapy water.
’ pr900ea
INSPECTION OF PUSH ROD
032
Check the push rod and socket for damage. Check
for cracks when the ball and socket are pushed into
the tube.
PrSOOsd
032
Check the roundness and straightness of the push
rod.
prl bdsb

Install the push rod in the socket of the valve tap-
pet.
Add clean engine oil to the push rod socket.
pr900hd
Check that the rocker lever adjustment screw

moves back fully.
rh9ssna
INSPECTION OF TAPPET
Check the socket, stem, and face for excessive wear,
cracks, and other damage. 042
Visual limit
(A) - normal contact

(B) and (C) - abnormal contact: do not reuse.
It is possible to use the tappet even
if there is a hollow in the tappet
face.
bp9tasa
032
The following standards show the permissible size
2
of the hollows.
1. A single hollow must not be greater than 2 mm.

2. The tappet cannot be reused if there are con-
nected hollows.
m
3. The total for multiple hollows must not exceed
4% of the tappet face or a diameter of 6 mm . 3
0 ::-.
4. There must be no hollow at the edge of the tap-
pet wear surface.
+
&&+a
Measure the valve tappet stem.
Diameter
mm
15.936 Min
15.977 Max
10mm
kf900tb
13-314
0
INSPECTION OF PUSH ROD

Wash the push rods in hot soapy water.
035
Check the push rod ball and socket for damage.
Check for cracks when the ball arid socket are press
fitted into the tube.
DrSOOsd
0
Check the roundness and straightness of the push a
rod.
prl bdsb
13-315
0
DISASSEMBLY AND ASSEMBLY ENGINE MOUNT GROUP
ENGINE MOUNT GROUP

OUTLINE OF FLYWHEEL HOUSING
To match the various uses, several sizes and styles
of flywheel housing can be used. If a ring dowel is
used, it is possible to position the housing to an
indicated overall face runout of within 0.20 mm
{0.008 in}. Make dowel holes in the housing being
used. There is no need to carry out the doweling
again. If you want to know the correct part num-
bers for the engine being used, check in the appli-
cable parts book or engine parts list.
OUTLINE OF FLYWHEEL, RING,

GEAR
The flywheel can only be used as an assembly. The
assembly consists of the flywheel and ring gear. It
is possible to carry out maintenance of the ring
gear.
OUTLINE OF FRONT SUPPORT

Depending on special uses, it is possible to use
various front engine mounts.
13-316
0
DISASSEMBLY AND ASSEMBLY FLYWHEEL, RING GEAR
FLYWHEEL, RING GEAR

INSPECTION OF FLYWHEEL, RING
GEAR
Check the ring gear teeth for wear and damage.
Use a color test to check for cracks in the mount-
ing hole. Checkfor cracks and damage to the clutch
face. If a flex plate is installed, check the flex plate
for cracks and damage.
Caution: If the ring gear teeth are worn or dam-

aged, replace the ring gear.
REPLACEMENT OF FLYWHEEL,
RING GEAR
Preparatory work:
RI
l Remove the transmission. 63
Q
REPLACEMENT OF RING GEAR
18 mm
Remove the flywheel.
f h900mb
Brass drift pin
Warning: When pushing the gear out from the fly-

wheel, wear protective glasses. Never
use a steel drift pin.
Use the drift pin to push the ring gear out from the
flywheel.
A
-
f h9sema
Heat the new ring gear in a heated oven for 20 min-

utes at 127 “C.
DISASSEMBLY AND ASSEMBLY FLYWHEEL, RING GEAR
Warning: When installing the heated gear, wear

protective gloves.
Install the ring gear. Set the tooth bevel facing the
crankshaft end of the flywheel, and install the ring
gear.
I f hleewb
Use two of the mounting bolts installed to the front
of the crankshaft or use a similar tool to hold the
crankshaft while tightening the flywheel mounting
bolts.
fw9cshb
18 mm torque wrench
Tighten the mounting bolts in the order shown in l3l

the diagram.
w: 137 Nm i14.0 kgm}

(K
0
w
f h900oa
REPLACEMENT OF RING GEAR

Brass drift pin
Warning: When pushing the gear out from the fly-

RI
wheel, wear protective glasses.
A
Using the drift pin, push the ring gear out from the
flywheel.
Caution:The ring gear of the flex plate application

6%
Q
cannot be replaced as an individual unit.
The complete flex plate assembly must be
replaced.
r9rsma
13-318
0
FLYWHEEL, RING GEAR
DISASSEMBLY AND ASSEMBLY FLYWHEEL HOUSING
Heat the new ring gear in a heated oven for 20 min-

utes at 127 “C.
Soewa
Warning: When installing the heated gear, wear

protective gloves.
Install the ring gear. Set the tooth bevel facing the
crankshaft end of the flywheel, and install the ring
gear.
f h9senb
I
FLYWHEEL HOUSING
REPLACEMENT OF REAR OIL SEAL
REMOVAL
If the crankshaft seal is wearing the flange groove,
install a wear sleeve to prevent leakage t3f oil.
-- 3s
1
Remove the drive line, and if the transmission is

installed, remove the transmission. % Q
@
t r9OOhd
!
19 mm
If the clutch and flywheel are installed, remove

them. For details of the procedure, see 7-25.
Remove the flywheel housing. For details of the
procedure, see 7-25.
Loosen the oil pan mounting bolts four turns.
10 mm
Remove the 4 mounting bolts holding the oil pan

to the rear cover.
Caution: Be extremely careful not to damage the

oil pan gasket when removing the gas-
ket from the rear cover. If the gasket is
damaged, remove the oil pan and replace
the gasket.
Insert a clearance gauge or shim stock between

the rear cover and the oil pan gasket. Move the
clearance gauge or shim stock backwards and for- op9csme
wards to remove the gasket from the rear cover.
Remove the mounting bolts from the rear cover,

then remove the cover from the crankshaft flange.
Remove the seal from the rear cover.
I ks9sem
Hammer, chisel
If there is already a wear sleeve installed to the

crankshaft, it must be removed before installing a RI
new wear sleeve.
Caution: Be careful not to chip the crankshaft with

the chisel or to make any dents. If the
c%
Q
crankshaft is damaged, replace it. A
Use a blunt chisel of the same width as the wear
sleeve. Tap one or two times with the hammer to
make a chisel mark in the wear sleeve. This will
cause the wear sleeve to expand, and it can then
be removed.
13-320
0

Clean the gasket surface of the cylinder block and
rear cover.
Using a crocus cloth, remove the rust or other de-
q
\
posits from the crankshaft flange.

Clean the crankshaft flange with a clean cloth.
I rc9sueb
Check the crankshaft flange for dirt or damage.
b
In
R I- ks9Olsv
(D
,
Check the rear cover for cracks or other damage.
ks9setc I
INSTALLATION
Caution: When installing the seal, do not use any
lubricant. Wash and dry the crankshaft \
La
and lip and check that the oil seal is cor-
rect before installing it.
ks9OOeh I
13-321
0
Caution: Install the service crankshaft oil seal (A)/

wear sleeve (B) assembly replacement kit
to the crankshaft as an assembly. Do not
remove the crankshaft rear oil seal from
the rear seal wear sleeve.
ks9seea
Install the rear cover and gasket.
Caution: Install the rear cover mounting bolts. Do

not tighten them. When installing the oil
pan, loosen the oil pan mounting bolts
and make a clearance at the rear cover and
at the gasket.
Caution: Using the seal mount, correct the align-

ment of the rear cover. After installing the
seal, to prevent the position of the seal
lip from moving, do not push the cover
or apply any force in any direction. rc900hd
Caution: For the wet flywheel housing oil seal, it is

necessary to apply soap around the out-
side diameter of the seal case. Nothing
is needed on the outside diameter of the
dry housing seal case.
ks9sewa
Using the service tool (Part No. 38240781, install

the oil seal/wear sleeve assembly. Install 2
threaded studs in the crankshaft mounting bolt
holes.
Coat the crankshaft, threaded studs, and crankshaft

rear seal/wear sleeve installation tool inside diam-
eter with a small amount of clean 15W-40 engine
oil.
ksltohd
13-322
0
Install the chamfered side of wear sleeve (A) to

the tip of crankshaft (B). Set installation tool (C)
with the counterbore end facing the top of the
threaded stud, and align the end of the crankshaft
so that it is perpendicular to the wear sleeve. In-
stall washers (D) and nuts (E) to the threaded stud.
Tighten the nuts in turn until the installation tool

contacts the end of the crankshaft.
ksltovh
Caution: To prevent the wear sleeve from binding

and irregular stretching, do not tighten the
nut more than 112 turns.
w: 20 Nm I2.0 kgm}
Install the installation tool and threaded stud.
10 mm
Align the rear cover ever with both sides of the oil
pan rail on the cylinder block.
w: 0T
Tighten the mounting bolts of the rear cover.
9 Nm IO.92 kgm}
13-323
0
Trim the gasket so that it is level with the oil pan

mounting surface.
Check that the trimmed pieces of the gasket do not
enter the engine.
F$PLAk;MENT OF FLYWHEEL
REMOVAL
Remove the transmission, clutch, and all related
component (if they are installed). Follow the in-
Remove the flywheel/ring gear assembly. For de-

tails of the procedure, see 7-23.
Support the engine properly to prevent damage.

Remove the connections of the battery cables.
Remove the starting motor.
st9OOmd
13-324
0
15 mm
Remove the mounting bolts and both rear engine

mounts.
Remove the mounting bolts.

The weight of the components exceeds 23 kg. Q
Gz
When lifting components, use a hoist or ask for
assistance, and take care to prevent injury.
Loosen the flywheel housing with a rubber ham-

mer.
Remove the flywheel housing and rectangular seal.
I fh9OOwb
A
tive clothing, safety glasses, and face
burns.
Clean the flywheel housing with steam

gent, then dry with compressed air.
or deter-
\
q
Be oarticularly careful of the bolt pattern portion

and check the-flywheel housing for cracks..
Check the surface visually for chips, flashes, and
cracks.
Use a fine cloth to remove the small chips or
flashes.
fh9OOsd
Check for damage to the thread caused by the in-

stallation of incorrect mounting bolts or mounting
bolts with incorrect gap between the threads. A
helicoil can be used to repair the damaged threads.
fh900se
INSTALLATION (DRY CLUTCH

SPECIFICATION)
Install the square seal and add Lubriplate 105.
Check the rear face of the cylinder block and the

mounting face of the flywheel housing visually to
check that it is clean, and check also for raised chips
or flashes.
Install the flywheel housing on top of the two ring

dowels.
Caution: When installing, check that the sealing ring

is not damaged.
fh900
13-326
0
15 mm
Tighten the mounting bolts of the flywheel hous-
0x
ing in the order shown in the diagram.
m:
zt iron housing : 77 Nm I7.9 kgm)
Aluminium housing : 60 Nm 16.1 kgm}
f hllcsoc
INSPECTION OF RADIAL RUNOUT OF

FLYWHEEL HOUSING
Connect a dial gauge to the crankshaft. Support
the dial gauge securely with a bar at the middle to
prevent it from hanging down. If the bar hangs
down or the indicator slips, it will be impossible to
obtain an accurate reading.
Set the indicator at the 6 o’clock position and set
the gauge to 0.
Rotate the crankshaft slowly. Note down the val-

ues (a), (b), and (c) for the 9 o’clock, 12 o’clock, and
r
3 o’clock positions on the concentricity work sheet.
Check again that the reading is 0 at the 6 o’clock
position.
The values at (a), (b), and (c) may be positive or
negative. See the diagram for the method of de-
termining the correct sign when recording the three
values.
fh9OOja
Rotate the crankshaft until the dial indicator is at

the 12 o’clock position, then set the gauge to 0.
Caution: Do not exceed the point where the bear-

ing clearance is removed or apply force
to the crankshaft. Do not use the flywheel
housing as a lever. These actions will
cause inaccurate readings of the bearing
clearance.
Using a lever, raise the rear of the crankshaft to the

upper limit. Note this value as (d) on the concen-
tricity sheet above. This value always becomes
positive when the bearing clearance in the perpen-
dicular direction is adjusted.
13-327
0
Using the concentricity work sheet, calculate the

values for “perpendicular
total”.
total” and “horizontal
I Concentricity Worksheet
The “horizontal total” is equal to the reading for 9

o’clock (a) minus the reading for 3 o’clock (c).
The “perpendicular total” is equal to the reading
for 12 o’clock (b) plus bearing clearance (d).
Example: 6 o’clock = standard =O

9 o’clock = (a) = 0.004”
12 o’clock = (b) = 0.003”
3 o’clock = (c) = 0.002” oi9OOvf
Using the work sheet and the example numbers,

we can calculate that the “horizontal total” equals
0.006” and the “perpendiculartotal” equals 0.005”.
Mark the value for the “horizontal total” on the

horizontal axis and the value for the “perpendicu-
lar total” on the vertical axis.
IONS
Using a ruler, draw the lines for the “horizontal to-
tal” and the “perpendicular total” to the point
where they intersect. If the intersection is inside
the shaded portion, the concentricity of the flywheel
housing is within the specified value.
If we use the example values given above for the I

I
TOTAL HORlZObjTAL READING oigoovg
“horizontal total” and “perpendicular total”, the
intersection is inside the shaded portion, so the
concentricity of the flywheel housing is within the
specified value
If the intersection is not inside the shaded portion,

remove the ring dowel and position the housing
again.
Caution: The ring dowel is not necessary for main-

taining the concentricity of the housing.
The force of the mounting bolts holds the
housing at the set position.
When the ring dowel is discarded, install the fly- f h9OOha

wheel housing to the engine.
When positioning the housing, tighten the mount-

ing bolts enough to hold the flywheel housing in
position. However, when tapping with the mallet,
loosen the bolts enough to allow a certain move-
ment.
Check the concentricity again. If the concentricity

is within the standard value, tighten the mounting
bolts to the specified tightening torque.
13-328
0
INSPECTION OF FACE RUNOUT OF

FLYWHEEL HOUSING
Caution: Be careful not to let the tip of the dial
indicator enter the mounting bolt hole. A
If it enters the hole, the gauge may be 4~
damaged.
@@
0a
Install the dial indicator as shown in the diagram.
Caution: To ensure the accuracy of the reading, use

a sturdy connecting bar. The bar must not
bend. Set the indicator to the 12 o’clock
position. Adjust the dial so that the indi-
cator points to 0.
042
Rotate the crankshaft slowly and note down the
readings at the 3 o’clock, 6 o’clock, and 9 o’clock
positions.
Caution: Push the crankshaft towards the front of

the engine to remove the clearance of the
crankshaft in the axial direction each time
the position is measured.
fh900ia
Continue to rotate the crankshaft until the indica-

tor comes to the 12 o’clock position. Check the
indicator to confirm that the needle is pointing to
the ZERO position. If it is not pointing to 0, the
readings will not be accurate.
jf
Calculate the total range for the indicator readings.
Example mm
12 o’clock 0.00
3 o’clock +0.08
6 o’clock -0.05
9 o’clock +0.08
TIR 0.13
fh900j i
13-329
0
The maximum permissible value for the total indi-

cator range (TIR) is determined by the diameter of
the housing bore. If it is not within the specified
range, replace the housing.
Bore diameter Max. permissible TIR

SAE
mm mm
2 447.68 - 447.80 0.20

3 409.58 - 409.70 0.20
fh900i
Install both rear engine mounts.

Install the flywheel and clutch (if equipped). Fol-
low the instructions from the manufacturer.
Install the transmission and related components.
Follow the instructions from the manufacturer.
I am900hc
Install the starting motor.

Connect the battery cables.
t900hc
INSTALLATION (WET CLUTCH

SPECIFICATION)
Except for the procedure given below, follow all
the procedures for installing the dry clutch.
Coat the flywheel housing drain plug with pipe seal-
ant, and install it in the hole at the bottom of the
flywheel housing.
Tighten the plug.
If the size of the plug is different, see Section for .&@
details of the tightening torque for the pipe plug.
fh9Dxhc
13-330
0
Install the plastic plug in the tachometer drive ac-

cess hole.
13 mm
Install the access plate and a new gasket. RI

Install the mounting bolts and tighten them.
m: 24 Nm 12.4 kgmj
fh9PIhb
Wash the assembly surface of the flywheel hous-

ing and cylinder block. Make sure these surfaces
are clean and have no oil or dirt on them.
Caution: The mounting holes on the mounting pads

are drilled through.
Coat the stopper screws with Loctite TM
277 and install them in the holes.
Installation depth of stopper screw

mm
0.00 Min
3.00 Max
Coat a continuous bead of Three Bond around all

the mounting bolt holes in the flywheel housing
mounting face.
wa
Coat the thread of the mounting bolts with Loctite

TM 277.
Install the mounting bolts and tighten them.
w: 60 Nm IS.1 kgm}
Install the plug in the barring gear hole.
I I I II f h9pxhf
INSPECTION
04E
Inspect the flywheel housing for cracks, and par-
ticularly for cracks in the bolt pattern portion.
f h900sd
Check that there is no bending of the mating thread

of the mounting bolts or damage to the thread
caused by installing improper mounting bolts. A
helicoil can be used for repairing the damaged
thread.
f h9OOse
13-332
0
INSTALLATION
Coat the drain plug with LG-7 and install.
Torque value
Cast iron : 55 Nm I5.6 kgml
Aluminium : 35 Nm (3.6 kgm1
Screwdriver
Install the plastic plug in the tachometer probe hole.
Install the expansion plug in the barring tool hole.
fh9pxhf
Coat both faces of the inspection plate gasket with

LG-7.
fh9skra
FLYWHEEL HOUSING
DISASSEMBLY AND ASSEMBLY FRONT SUPPORT
13 mm
Install the inspection plate.
w: 24 Nm 12.4 kgm}
Wet clutch specification
Except for the procedure given below, follow all

the procedures for installing the dry clutch.
Coat the flywheel housing drain plug with pipe seal-
ant, and install it in the hole at the bottom of the
flywheel housing.
Tighten the plug.
I coa I I fh9raxhd
The mounting bolts on the mounting pads are

drilled through. Coat the stopper screws with
Loctite TM 277 and install them in the holes.
Installation depth of stopper screw

mm
0.00 Min
3.00 Max
FRONT SUPPORT
Wash the parts with detergent.
Check the parts for cracks or damage.
13-334
0
DISASSEMBLY AND ASSEMBLY REMOVAL OF ENGINE
REMOVAL OF ENGINE
When removing the hoses, lines, link mechanisms,
or electrical connections, mark with tags to distin-
guish the position of installation.
Remove the connections of the battery cables.

Drain the engine coolant.
oibooma
Drain the oil.

Disconnect the starter cable, engine ground strap,
cab or chassis, to engine hoses, tubing, electrial
wires and hydraulic lines.
Remove the joints of the intake and exhaust pipes.

Remove the engine driven accessories installed to
the chassis.
c%
Q
DISASSEMBLY AND ASSEMBLY REMOVAL OF ENGINE
Remove the throttle link mechanism from the fuel

injection pump control lever.
Remove the drive unit from the flywheel.
bP9OOme
Warning: When using a refrigerant line (air con-

ditioning), wear protective glasses and
protect your face, wrap cloth around the
fittings, then remove them. Be ex-
tremely careful not to get refrigerant in Refriaer:nt
your eyes or on your skin. This may
cause serious injury.
When removing the engine from the equipment,

remove all chassis components that will make it
easier to remove the engine.
.<-
.:_---:_
./’
ew900ma
Caution: For applications connecting the rear en-

‘L...
gine mount to the transmission, the en-
gine and transmission may have to be
removed as one unit.
A
Warning: Be sure to use engine lifting equipment
that is designed to raise the engine and
transmission safely as one unit.
,$@
en9OOhb
13-336
0
REMOVAL OF ENGINE
DISASSEMBLY AND ASSEMBLY INSPECTION OF ENGINE MOUNT
Connect a hoist of the correct rating and the en-

gine lifting installer to the engine. lifting bracket,
then remove the engine.
Caution: When not removing the transmission, put

supports under the transmission to pre-
vent it from falling.
Cover the openings in the engine to prevent dust

from entering the engine.
Set the engine on a suitable engine support stand.
Remove any other accessories or brackets that are

to be used on the replacement engine. % 0
INSPECTION OF ENGINE
MOUNT
0s
Check the rubber cushion mount for cracks or dam-
age.
Check the mounting bracket for cracks or damage
to the bolt holes.
Caution: If the engine mount or bracket are dam-

aged, it will cause misalignment of the
engine and damage to the drive compo-
nents, and will also cause problems of
vibration.
13-337
0
DISASSEMBLY AND ASSEMBLY INSTALLATION OF ENGINE
INSTALLATION OF ENGINE
Install the accessories and br
the previously used engine.
Caution: For applications connecting the rear en-

gine mount to the transmission, the en- LT
gine and transmission may have to be

installed as one unit. I
Warning:Be sure to use engine lifting equipment

that is designed to raise the engine and
transmission safely as one unit.
ew9OOhb
Connect a hoist of the correct rating and the en-

gine lifting installer to the engine lifting bracket,
then install the engine.
.J,
ew9OOws
Center the engine inside the chassis, then tighten

the engine mounting bolts. For details of the tight-
ening torque, see the manufacturer’s specifications.
Connect the removed engine and chassis mounted
accessories.
Caution: Check that the lines, hoses, and tubes are

positioned and held in place so that there
is no damage. Check that the connection
of the intake and exhaust pipes is com-
pletely sealed and that there is no leak-
age.
13-338
0
Caution: When installing the radiator cap at this

point, it is important to remove the air A
from the cooling system. If the air is not
removed properly from the cooling sys-
tem, it will cause overheating and dam-
age to the engine.
Carry out a final check to confirm that the hoses,

s
0
wires, link mechanism, and components are prop-
erly installed and tightened.
Remove the wire from the fuel solenoid, or set the

mechanical fuel shut-off to the OFF position and
check that the fuel is shut off. This inspection is
63
Q
necessary to prevent the engine from starting when
carrying out the pressurizing system for the lubri-
cating oil rifle pressure.
Caution: Do not rotate the starting motor continu-

ously for more than 30 seconds. Stop the
starting motor and wait for 2 minutes to
let the starting motor cool down.
Run the engine until the oil pressure gauge indi-

cates the standard pressure.
After checking the pressure, connect the wire to

the fuel solenoid.
13-340
0
Open the bleed the screw and prime the low-pres-

sure fuel system.
Operate the plunger of the fuel feed pump until no
more bubbles come out with the fuel from the fit-
ting.
Tighten the bleed screw.
fS9OOWP
Run the engine at low idling for 2 - 3 minutes.
Warning: Do not remove the radiator cap when

the engine is hot. Hot steam will come A
out and cause serious burns. Wait for
the engine coolant temperature to go
down below 50 “C.
Shut off the engine, wait for 5 - 7 minutes for the

oil to drain to the oil pan, then check the oil and a
0
coolant levels again.
2-3 Minutes 6-f Minutes
If necessary, add oil or water to the correct oil level

or coolant level.
Run the engine at 1000 - 1200 rpm for 8 - 10 min-

utes. Checkfor normal operation, abnormal noise,
leakage of coolant, leakage of fuel, and leakage of
oil.
Repair any leakage and problems with the compo-
nents. For details, see the applicable procedure.
For details of the procedure for running in the en-
gine and testing, see Section 8.
8 to 10
Minutes
DISASSEMBLY AND ASSEMBLY OIL PAN AND SUCTION TUBE
OIL PAN AND SUCTION TUBE

Index No. Part Name Qw Remarks
1 Oil pan 1
2 Threaded plug 1 Ml8 - 1.5 x 12 mm
3 Sealing washer 1 Thickness 1.5 mm, 18.40 I.D.
4 Hexagonal mounting bolt 3 M8-1.25x16mm
5 Oil suction connector 1
6 Hexagonal mounting bolt 36 M8-1.25x20mm
7 Spring washer 36
8 Spring washer 1 Thickness 1.5 mm, 22.2 I.D.
9 Threaded plug 1 M22 x 1.5 mm
10 Oil pan head plate 1
11 Flange gasket 1
13-342
0
REPLACEMENT OF OIL PAN, SUC-

TION TUBE, GASKET
17 mm
Drain the oil.
Exl
Caution: Use a container with a capacity of at least
20 liters (15 U.S. quarts).
Q
63
oP9OOwa
10 mm
Remove the oil pan.
op900mc
10 mm
Remove the suction tube.
opltbmb
Check the suction tube for cracks.

Clean the gasket surface.
10 mm
Install the suction tube and a new gasket.
m: 24 Nm 12.4 kgm}
Fill the space between the oil pan rail, gear hous-
ing, and rear seal housing with Three Bond 1207-
C.
IOmm
Install the oil pan and gasket.
m: 24 Nm I2.4 kgm}
13-344
0
OIL PAN AND SUCTION TUBE
DISASSEMBLY AND ASSEMBLY REGULATOR VALVE
Check the suction tube and brace for cracks. Do

not reuse the suction tube or brace if there are any
cracks.
Check the block mounting surface for cracks.
REGULATOR VALVE
REPLACEMENT OF REGULATOR
VALVE, SPRING
DISASSEMBLY
Clean the area around the pressure regulator plug
thoroughly, and be careful not to let dirt get into \
q
the plunger bore when removing the plug.
19 mm
Remove the threaded plug, spring, and plunger. KLI

Service hint: Normally, when removing the plunger,
insert one finger in the plunger bore and pull it up.
If the plunger cannot be removed in this way, the
63
Q
plunger is stuck, so remove the housing, then take
out the plunger and clean it.

Wash the components thoroughly in clean solvent,
then dry with compressed air.
Caution: If it is necessary to clean the plunger bore,

remove the housing to prevent dirt from
entering the engine. If the piston ring seal-
ing is defective, oil will spurt out from the
breather tube or there will abnormal con-
sumption of oil (for details of measuring
the blow-by, see the section on base en-
gine components).
I c9v aeb
13-346
0
Check the plunger and bore.

and bore thoroughly.
Polish the plunger
s
0-
0*
Check that the plunger slides smoothly in the bore.
ASSEMBLY
19 mm
Install a new sealing O-ring to the threaded plug,
then add clean engine oil. Install the pressure
regulator assembly.
w: 80 Nm 18.2 kgm}
DISASSEMBLY
19 mm
Remove the plug and sealing washer.

Remove the spring and plunger.
lc9pxme I
INSPECTION
0s2
Check the plunger bore for chips or damage.
The plunger must move freely in the bore.
Check the pressure regulator spring at the follow-

ing two heights.
Free height 60.6 mm

Limit
1991
. 44.5 mm -min. load 105 N 110.7 kg1 (regu-
lator valve opens)
l 41.25 mm -min. load 142 N U4.5kgI (regu-
lator valve seated)
Free height 66 mm
Limit
(1994)
l 44.5 mm - min. load 116 N {I 1.8 kg) (regu-
lator valve opens)
l 41.25 mm -min. load 137 N (14.0 kg} (regu-
lator valve seated) I c9spna
ASSEMBLY
19 mm
Install the valve.
m: 80 Nm 18.2 kgm1
Ic9pxha
13-348
0
DISASSEMBLY AND ASSEMBLY OIL FILTER BYPASS VALVE
OIL FILTER BYPASS VALVE

REPLACEMENT
Remove the valve from the cooler cover.
I c9ePma
Tap the new valve until it contacts the step in the

bore.
lc9ePha
13-349
0
DISASSEMBLY AND ASSEMBLY OIL COOLER
OIL COOLER
Index No. Part Name WI Remarks
1 Hexagonal flange head mounting bolt 14 M8 x 1.25 x 35

2 Bypass valve 1
3 Compression spring 1
4 Pipe plug 1 l/8 NPT
5 Lubricating oil filter head 1
6 Filter head adapter (impossible to replace) 1
7 Cooler core 1
8 Filter head gasket 1
9 Threaded plug 1 M22 x 1.50
10 O-ring seal 1
11 Pressure regulator plunger 1
12 Oil cooler core gasket 1
13 Lubricating oil filter cartridge 1
13-350
0
DISASSEMBLY AND ASSEMBLY OIL PUMP
OIL PUMP
I PSOOsd
Index No. Part Name Qw Remarks
1 Lubricating oil pump 1 (Note I)

2 Lubricating oil pump body 1
3 Sleeve bearing 1
4 Lubricating oil pump idler shaft 1
5 Oil rifle plug 1
6 Screw 2
7 Lubricating oil pump shaft 1
8 Lubricating oil pump drive gear 2
9 Lubricating oil pump idler gear 1
IO Key 1
11 Gerotor, Driver 1
12 Gerotor, Planetary 1
13 Plate, Lube pump back 1
14 Hexagonal mounting bolt 4 M8- 1.25x30
Note 1: Item 1 can only be used as an assembly. The disassembly and assembly drawing is given for
explanation.
13-355
0
REPLACEMENT OF OIL PUMP

Preparatory work:
l Remove the drive belt.
Caution: Before removing the belt, loosen the

crankshaft pulley to make it easier to re-
move the belt.
15 mm
Remove the crankshaft pulley. l.!u

%Q
' da900mb 1
10 mm
Remove the front cover.
REMOVAL OF OIL PUMP

13 mm
Remove the 4 mounting screws.

Remove the pump from the block bore.
13-356
a

When inspecting the oil pump to judge if it can be
used again, do the following.
0@
Check the pump gear visually for chips, cracks, and
wear.
I p900sa
Remove the back plate.
IPSDlmb
Make a TOP mark on the planetary portion of the

Gerotor.
I P900SC
Remove the planetary portion.

Check for wear or damage.
I PSOOmc
q
Wash all the disassembled parts in solvent, then \
dn/ with compressed air.
032
Check the pump housing and Gerotor drive for
damage and wear.
Caution: Always install the planetary portion to its

original position.
Install the planetary portion.
Measure the clearance at the tip of the planetary

portion.
Wear limit
Max. permissible clearance: 0.1778 mm
I D900n
13-358
0
Measure the clearance from the Gerotor drive/plan-

etary portion and port plate.
Wear limit
I p900nh
Measure the clearance between the planetary por-

tion and the Gerotor bore.
Wear limit
Ip900nI
Measure the backlash of the gears.
Wear limit (pump being used)

mm
0.076 Min
0.330 Max
I PSOOnd
Install the back plate.

INSTALLATION OF OIL PUMP

Caution: If the pump is not filled with oil when it is
installed, the priming will be delayed A
when the engine is started, and this will
damage the engine.
Lubricate the pump with clean engine oil.
Caution: Check that the idler gear pin is in the block

positioning bore. A
Install the pump.
13 mm
Tighten the bolts in order shown in the diagram.
m: 24 Nm I2.4 kgm}
0K a-
Caution: Make sure that the pump back plate is

seated on the bottom of the block bore.
If the installation of the pump is correct,
the pump flange will notcontact the block.
I p900wd
13-360
0
Caution: When installing a new pump, check that

the backlash of the gears is correct. Mea-
sure the backlash of the gears.
Backlash limit
A B
0.076 - 0.330 mm 0.076 - 0.330 mm

both gears.
INSPECTION
Check the hydraulic oil pump gear visually for peel- UJ
ing, cracks, and excessive wear.
I p900nh
0s
Remove the sealing plate.
I p900sa
Make a TOP mark on the Gerotor planetary por-

tion.
lp9pimb
13-361
0
Remove the Gerotor planetary portion.

Check for excessive wear or damage.
Wash all the parts in detergent,

pressed air.
then dry with corn-
q
\
033
Check the pump housing and Gerotor drive for
damage and excessive wear.
I PShs
Check that the Gerotor planetary portion is in-

stalled to its original position.
Install the Gerotor planetary portion.
13-362
0
Clearance at tip
Diameter
mm
0.1778 Max.
Measure the clearance at the Gerotor drive/Gerotor

planetary and port plate. @
Clearance of port plate

mm
0.127 Max.
I I PSOOnh
Measure the clearance between the Gerotor plan-

etary and body bore.
Clearance of body bore

mm
0.381 Max.
IP900ni
Measure the backlash of the gear.
Limit for a “Used pump”
0.076 - 0.015 mm

both gears.
I p900nd
13-363
0
Install the back plate of the lubricating oil pump.
IPSPlhb
13-364
0
FUEL INJECTION PUMP GROUP
FUEL INJECTION PUMP GROUP

Bosch VE
Lucas CAV
Stanadvne 064
e43
II- 2 -
blippondenso EP9
Bosch P7100
ip9OOsl
13-365
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION NOZZLE GROUP
FUEL INJECTION NOZZLE GROUP

ft900ar
13-366
0
FUEL INJECTION NOZZLE

DISASSEMBLY
Clean the carbon deposit from the nozzle. Use a
brass wire brush and put test oil on a hard piece of
\
q
wood to clean.
I I I f i900eh
Remove the copper sealing washer and dispose of

03
Q
&\
it.
z
15 mm
i&l f i9sema
Hold the nozzle holder in a soft jawed vice and re- RI

move the nozzle nut.
c%
0
f i900fb
Remove the nozzle needle valve and intermediate

plate.
Caution: To prevent damage, insert the injector

BQ
nozzle and needle valve into a bath filled
with clean test oil.
f i900fc
13-367
0
Caution: Support the needle valve only with the

stem. Skin oils will corrode the finely AA
lapped surfaces.
f i900va
Caution: Keep the needle valve and nozzle tip in

sets to prepare for installation.
A
88 %I
f i 9OOw2
Remove the nozzle holder from the vice. Remove

the pressure spindle, pressure spring, and shim.
f i9OOfd

The edge type filter can be cleaned by blowing com-
pressed air through the fuel passage from the
nozzle end of the nozzle holder. The edge type fil-
ter cannot be removed for maintenance.
q\
Rinse the new nozzle and needle valve in deter-

gent, and wash thoroughly to remove the protec-
tive covering completely.
f i900eo
13-368
0
Cleaning kit (795-799-1310)
Caution: When cleaning the nozzle, never use em-

ery paper or any metal scraper.
As shown in the diagram, put test oil on the scraper

A
and clean the nozzle seat. Put test oil on a hard
piece of wood and polish the needle seat. q
\
f i9bres
q
As shown in the diagram, clean the ring groove \
inside the nozzle with a scraper. Rinse in solvent
and remove the dirt and carbon deposit, then ap-
ply clean test oil.
f i9breh
As shown in the diagram, clean the injection port

q
\
of the hole type nozzle with a cleaning needle that
matches the size of the port.
Remove any marks of burning from the nozzle with
industrial use detergent. Rinse all parts in clean
test oil.
I I I f i9OOee
q
Clean the needle valve tip with a brass wire brush. \
Check the surface for roughness and corrosion.
Normally, the pressure shoulder has the remains
of rough machining.
Caution: If the needle valve is deteriorated, replace

it as a unit with a nozzle that has inter-
changeability.
f i9Dssa
Dip the needle valve in clean test oil and insert the
needle valve all the way into the nozzle body. HH
f i9vawa
Caution: If any needle valve and nozzle does not

pass this test, replace the assembly.
Pull the needle valve out l/3 from the nozzle body.
The needle valve must slide back into the nozzle
body completely under its own weight.
If the nozzle does not pass the slide test, clean the
nozzle again and repeat the test.
f i9Dssb
ASSEMBLY
Caution: Check that the assembly surface and pres-
sure surface are completely clean, then
add fuel oil before assembling.
Caution: Install the same thickness of shim as was

removed during disassembly. Using the
pressure spring, check that the shim is
installed flat.
Install the shim.
f i9smha
13-370
0
Hold the nozzle holder in a soft jaw vice and install

the spindle.
f i900ce
Install the intermediate plate.
f i9OOad
Install the needle valve and nozzle assembly.
f i900ce
15 mm
Install the nozzle nut.
m: 30 Nm 13.1 kgm}
TEST
A
Warning: Be careful not to get the test spray on
yourself. If this fluid gets into the blood-
stream, it will cause septicemia, which
may lead to death.
All nozzle must be tested for opening pressure, A
chatter and spray pattern.
I
,
f i900sa
Test the opening pressure.
a. Open the valve.

b. Operate the lever one stroke every second. 1 ’
0
’ I
\ I
c. Read the displayed pressure when the spray /
_
.‘I00 2w ’
starts.
---r
‘.,O 300 ,.-
f i9OOda
If the port pressure is not within the specification

value, replace the shim pack. If the shim thickness
is increased, the pressure will rise.
f i900oa
Leakage test:
a. Open the valve.

b. Operate the lever and keep the pressure 14.6 kg/
cm2 (20 bar} lower than the port pressure.
c. No drops must come from the tip within 10 sec-
onds.
10 Seconds
13-372
0
FUEL INJECTION NOZZLE GROUP.
DISASSEMBLY AND ASSEMBLY FEED PUMP
Chatter test
The chatter test is used to check if the needle valve

moves freely and has the capacity to vaporize the
fuel properly.
The chatter of a used nozzle must not be evaluated
at low speed.
Generally speaking, a used nozzle can continue to
be used if it passes the leakage test and there is
only slight vibration which can be heard when the
lever is operated at high speed, and the fuel is
sprayed uniformly.
FEED PUMP (CYLINDER

BLOCK MOUNT TYPE)
REPLACEMENT OF FEED PUMP
(DIAPHRAGM TYPE)
Preparatory work
l Remove the connection of the low-pressure
fuel line.
IO mm
Remove the fuel feed pump, then do as follows.
Clean the cylinder block mounting surface.

\
q
-
10 mm
Install a new gasket to the fuel feed pump.
m: 24 Nm 12.4 kgm}
fs900hl
14 mm and 17 mm
Install the low-pressure fuel line.
_
---_._-___
____
---- --__
, ----___
I
.d
I
IO mm
Open the banjo bleed screw and bleed the air from
the low-pressure fuel line.
IO mm
Operate the hand lever until no more
come out with the fuel from the fitting.
13-374
0
REPLACEMENT, ASSEMBLY OF
FEED PUMP (PISTON TYPE)
Preparatory work:
l Clean the dirt from the fuel line fitting and
fuel feed pump.
REMOVAL
14 mm, 17 mm, 20 mm wrench
Remove the fuel line from the fuel feed pump and
fuel filter head.
Using two wrenches, remove the fuel line from the
fuel feed pump.
q
10 mm wrench
Remove the fuel feed pump.

Clean the cylinder block mounting surface.
BQ
q
\
20 mm, 26 mm wrench
Caution: The hand prime fitting and inlet port fit-

ting are spring type fittings. If these two
w-
A
OU tlet Fitting Inlet Fitting
!iLiime
fittings are removed suddenly, you may
injure yourself.
Fix the fuel feed pump in a vice. When doing this, B0

be careful not to damage the pump housing.
Remove the rubber boot from the hand prime fit-
ting.
Remove the three fittings shown in the diagram.
fs9hsea
13-375
0
Remove all the internal components from the fuel

feed pump.
Caution: Check that the checkvalve gasket has been

removed from the inlet port fitting.
(A) Outlet port fitting

(B) Inlet port fitting
(C) Hand prime fitting
I fs9OOfa
CLEANING
Wash the fuel feed pump thoroughly with deter-
gent to remove the dirt.
f s9OOea
ASSEMBLY
20 mm, 26 mm wrench
Use the new components in the reassembly kit and

assemble the fuel feed pump.
1. Check valve
2. Check valve gasket
3. O-ring seal
4. Outlet port fitting/check valve
5. * O-ring seal (25 mm)
6. * O-ring seal (30 mm) or (25 mm)
* The necessary O-ring is decided by the di- f s9OOaa

mensions of the inlet port fitting. Discard
unused O-ring.
Caution: Check carefully that the check valve is in-

stalled so that it opens in the direction of
the fuel flow.
If there is a mistake in the installation of the check

valve, the engine output will drop.
13-376
0
DISASSEMBLY AND ASSEMBLY FEED PUMP, FUEL LINES
Fix the fuel feed pump in a vice and tighten the

fittings to the following values.
(A).Outlet port fitting : 30 Nm 13.1 kgm1

(6) Hand-Prime fitting : 30 Nm (3.1 kgm1
(C) Inlet fitting : 30 Nm (3.1 kgm)
f s9OOwb
INSTALLATION
10 mm
Caution: Tighten the mounting bolts uniformly in

turn. When tightening the mounting A
bolts, push the fuel feed pump plunger
into the pump. If the mounting bolts are
not tightened uniformly, the plunger will
be bent or damaged.
Install the pump. %0

G w: 24 Nm I2.4 kgm)
fs9OOhb
%
6
14 mm, 17 mm, 20 mm wrench
Install the fuel line to the fuel feed pump and fuel
filter head. Tighten the connection to the pump
with two wrenches.
w: 24 Nm I2.4 kgm1
For details of venting the low-pressure fuel line,

see procedure 5-l 5.
0
Check the fuel feed pump for cracks or damage
which make it impossible to reuse it. Check for @
traces of fuel leakage from the weep hole portion.
Wash the pump with mineral oil, then dry with com-
pressed air.
\
cl
Check the camshaft lever and return spring for ex-

cessive wear. s
0
When checking the fuel feed pump, pour clean die-

sel fuel or engine oil into the inlet port connection
and carry out the following test.
fs900vb
Block the fuel inlet port line with your finger, then
operate the priming lever and check the diaphragm.
If there is no problem in the pump, the suction force
will not go down until you remove your finger from
the inlet port.
With the diaphragm type fuel feed pump, it is not

practical to replace parts.
Handle the pump as an assembly.
With some repair kits, it is possible to use the op-

tional piston type pump which can be washed and
repaired. I
13-378
0
ASSEMBLY (PISTON TYPE)

Preparatory work:
l Wash the dirt and dust off from the fuel line
fitting and fuel feed pump.
29 mm, 26 mm wrench
Caution: The hand prime fitting and inlet port fit- RI Inlet Fitting
Outle,t Fitting
ting are spring type fittings. If these two
fittings are removed suddenly, you may A /
Hand Prime
injure yourself. Fitting
Fix the fuel feed pump in a vice. Be careful not to 63 Q
damage the pump housing.
Remove the rubber boot from the hand prime fit-
ting.
z Remove the three fittings shown in the diagram.
z f sQhsc+r
6
Remove all the internal components from the fuel

feed pump.
Caution: Check that the check valve gasket has been

removed from the inlet port fitting.
(A) Outlet port fitting

(B) Inlet port fitting
(C) Hand prime fitting
fs9OOfa
CLEANING
Wash the fuel feed pump thoroughly with deter-
gent to remove the dirt.
fs900ea
FEED PUMP
DISASSEMBLY AND ASSEMBLY REPLACEMENT OF FUEL FILTER
ASSEMBLY
20 mm, 26 mm wrench
Use the new components in the reassembly kit and

assemble the fuel feed pump.
1. Check valve
2. Check valve gasket
3. O-ring seal
4. Outlet port fitting/check valve
5. * O-ring seal (25 mm)
6. * O-ring seal (30 mm) or (25 mm)
f s9OOaa
*The necessary O-ring is decided by the di-
mensions of the inlet port fitting. Discard
unused O-ring.
Caution: Check carefully that the check valve is in-

stalled so that it opens in the direction of
the fuel flow.
If there is a mistake in the installation of the check

valve, the engine output will drop.
Fix the fuel feed pump in a vice and tighten the

fittings to the following values.
(A) Outlet port fitting : 30 Nm 13.1 kgm1

(B) Hand-Prime fitting : 30 Nm 13.1 kgm1
(C) Inlet fitting : 30 Nm I3.1 kgm}
f s9oow
REPLACEMENT OF FUEL
FILTER
80 - 95 mm, filter wrench
If used, remove the two filters from the fuel filter

adapter.
13-380
0
DISASSEMBLY AND ASSEMBLY REPLACEMENT OF FUEL FILTER
80 - 95 mm, filter wrench
If they are being used, remove the two filters from

the dual filter adaoter. /D,
If there is any leakage, remove the dual filter

adapter and replace the O-ring.
Q
m: 32 Nm I3.3 kgm) C%
ff9hdml
Fill the new filter with clean fuel.
Add clean lubricating oil to the seal.

0Da
I ff9etwb
13-38 1
0
REPLACEMENT OF FUEL FILTER
DISASSEMBLY AND ASSEMBLY FUEL PIPING
Caution: If the tightening is carried out by machine,

,
the thread may be shredded and the fil-
ter element seal and filter can may be
damaged.
Install the filter according to the instructions from

the manufacturer.
I / I Ifgethc
For models of the automobile 102 series engine

after 1991 which are equipped with the Bosch
P71 IO in-line fuel injection pump, the fuel filter is
installed to the rear of the intake manifold as shown
in the diagram.
FUEL PIPING
REPLACEMENT OF HIGH-PRES-
SURE FUEL PIPING (BOSCH VE,
LUCAS CAV)
17 mm
Remove the high-pressure fuel line from the injec-

tor, then do as follows.
Caution: Before removing, clean the area around

the fuel liie thoroughly.
10 mm
Remove the fuel line clamp mounting bolts from

the intake cover.
13-382
0
14 mm and 17 mm
Remove the fuel line from the fuel injection pump.
Caution: Use two wrenches to prevent the deliv-

en/ valve holder from rotating.
10 mm
Assemble the fuel line in the opposite order from

removal.
w: 30 Nm I4.1 kgm1
A
Warning: If fuel is spilled on to a hot exhaust mani-
so
fold, there is danger that it will cause fire,
do not bleed the air from a hot en-
gine.
Run the engine and bleed the air one line at a time
until the engine runs smoothly.
Stbua
REPLACEMENT OF FUEL SUPPLY I

PIPING (BOSCH VE, LUCAS CAV)
17 mm
Remove the bleed screw banjo fitting and do as

follows.
13-383
0
14 mm and 17 mm
Remove the fuel line from the Bosch fuel injection

pump fitting.
Caution: Use two wrenches when removing the fuel

supply line to prevent the inlet port fitting
of the fuel injection pump from becoming
loose.
ft9tbmi
14 mm, 16 mm, 19 mm, 24 mm
Remove the fuel supply line assembly from the two

Lucas CAV fuel injection pump fittings.
Caution: When disassembling the line, replace the

fitting seal.
ft9tbmj
17 mm
Install the fuel supply line in the reverse order to

removal. Tighten the fuel line securely to the fuel
injection pump fitting.
0<
QzEl for banjo screw: 32 Nm (3.3 kgm}
Operate the hand lever 10 - 20 strokes to fill the

fuel supply line.
13-384
0
CLEANING AND INSPECTION OF

HIGH-PRESSURE FUEL PIPING
0a
To make it easier to remove the injector, check
visually for damage to the high-pressure fuel line,
such as bending of the line. The high-pressure
pulse causes the injector line to expand and con-
tract, so internal peeling will occur at the bent
portion. Replace any bent line.
Wash the fuel line with clean detergent, then dry

with compressed air. Remove any loose paint.
\
q
032
Check both ends of the fuel line for cracks.
sb
-
Caution: Tghten the high-pressure line securely

so that the lines do not touch each other
032
or touch any other component. Check
the contact portions where the material
is worn.
Check the vibration isolators (clamp). Check that

thevibration isolators are correctly positioned and
tightened. If the isolator is damaged or improper
installed, it will usually lead to failure of the fuel
line.
Caution: Do not weld the line or use substitute

parts. Use only the part numbers speci- A
fied for the engine.
The length of the line, internal dimensions, and ri-

gidity are important elements for smooth opera-
tion of the engine. Use the provided metal tags to
mark each line with the part number to distinguish
it.
REPLACEMENT OF FUEL RETURN PIP-

ING (BOSCH VE, LUCAS CAV)
IOmm
Remove the mounting bolts from the mounting

clamps, then do as follows.
IO mm
Remove the banjo fitting screw and washer. _
13-386
0
17 mm
Remove the fuel drain line fitting.
Assemble the fuel drain line and fuel drain mani-

fold in the reverse order to removal.
Caution: Use a new seal for the fitting.
ft9tbhe
Tighten the banjo fitting screw.

Q~EI: 9 Nm IO.92 kgm}
Caution: Use a new sealing washer for the fuel
drain manifold. 0
q
f t9waha
0(K
Tighten the clamp mounting bolts.
w: 24 Nm I2.4 kgm}
13-387
0
CLEANING AND INSPECTION OF FUEL

DRAIN PIPING
0a
Check the fuel drain manifold for cracks and dam-
age.
Check the seal surface for traces of leakage.

04s
i t900sd
REPLACEMENT OF LOW-PRES-
SURE FUEL PIPING (BOSCH VE,
LUCAS CAV)
14 mm and 17 mm
Remove the line from the fuel feed pump and fuel
filter head.
ISI
Q
%
When replacing the fuel line, replace sealing

washer (I) of the banjo fitting each time it is re-
moved.
Install the fuel line and tighten the fitting securely.
ft9tbhc
13-388
0
iv mm
Open the banjo bleed screw and bleed the air from
the fuel line.
ft9tbwa
IO mm
Operate the hand lever until no more bubbles come

out with the fuel from the fitting.
CLEANING AND INSPECTION OF

LOW-PRESSURE FUEL PIPING
q
Wash the low-pressure fuel line with clean deter-
gent, then dry it with compressed air. \
f t900ed
Check the line visually

damage.
for cracks, wear, or other
0
a
f tsnnsr
13-389
0
REPLACEMENT OF AIR-FUEL RA-

TIO CONTROL TUBE (BOSCH VE)
12 mm
Remove the fuel tube from the manifold fitting and
pump.
Caution: When installing the tube, use a new seal-
ing washer. 0
CE
Assemble in the reverse order to removal.
@I/$
&@
13-390
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REPLACEMENT OF WATER PUMP

Preparatory work:
l Drain the coolant.
l Remove the belt.
13 mm
Remove the 2 mounting bolts, then remove the wa-

ter pump and do as follows.
p9bdma
Clean the mounting surface of the cylinder block.
lbdea
Install a new sealing ring in the pump groove.
wp9riha
13 mm
Install the water pump.
w: 24 Nm 12.4 kgm}
13-392
0
DISASSEMBLY AND ASSEMBLY WATER PUMP. FAN HUB
INSPECTION
043
Check the impeller plate for wear or corrosion.
wp9OOsd
0a
Check that the pump rotates freely.
wP900se
0
Checkfortraces of leakage from the weep hole seal. a
It is not practical to replace the parts. Handle the

water pump as an assembly.
WPSOOSf
FAN HUB
REPLACEMENT OF FAN PULLEY
Preparatory work:
l Remove the belt.
13-393
0
DISASSEMBLY AND ASSEMBLY FAN HUB
13 mm
Remove the 4 mounting bolts, then remove the fan

and spacer.
w: 24 Nm I2.4 kgml
REPLACEMENT OF FAN HUB

Preparatory work:
l Remove the belt.
l Remove the fan pulley.
IO mm
Remove the 4 mounting bolts, then remove the fan

hub.
w: 24 Nm I2.4 kgm}
fa900mc
INSPECTION
Check that the fan hub shaft rotates freely.
0
Check the edge of the bearing for traces of oil leak- s
age. If necessary, reassemble or replace.
fa9besd
13-394
0
033
Check the fan hub bearing for wear. The bearing
must have the minimal amount of side-to-side or
end play movement. If it is thought that it exceeds
the minimum value, replace the bearing.
fa9bese
DISASSEMBLY
16 mm
Fix the fan hub and remove the center bolt and
retainer. RI
%Q
f a9boma
Snap ring pliers

If there is a snap ring installed to the assembly,
remove the snap ring as shown in the diagram.
I
I fa9rrma
l-inch drift
Support the fan hub bracket housing and push out RI
the shaft/hub.
A force of approx. 6 tons is required.
a9bemc
13-395
0
Snap ring pliers
Turn the bracket housing, then remove the snap RI

ring (if one is installed).
fa9rrha
P-inch pipe
Push the outside diameter of the bearing and re-

move it from the housing.
f a9bemb
ASSEMBLY
Snap ring pliers
if a snap ring was installed to the bracket housing,

install the snap ring again.
2-inch pipe
Set the bearing facing the snap ring, and push

until it is level with the front of the housing.
13-396
0
Snap ring pliers
Install the record snap ring if so equipped.
fa9rrma
Support the bearing inner race with a 1.25-inch pip- 4~

ing joint, then push in fhe hub/shaft until it con- (@
tacts the bottom of the bearing. @
16 mm
Secure the assembly and install the retainer and

center bolt.
w: 77 Nm 17.9 kgm}
13-397
0
DISASSEMBLY AND ASSEMBLY BELT TENSIONER
BELT TENSIONER
f a900nx
Index No. Part Name Remarks
1 Fan support 1 Install to block

2 Ball bearing 1
3 Fan hub 2 Thickness 27.0 mm, diameter 25.4 mm shaft
4 Fan retainer 1
5 Hexagonal mounting bolt 1 M12-1.75 x 70 mm
8 Fan pulley 1
9 Clamping plate 1
10 Mounting bolt 4 M8-1.25 x 20 mm
11 Mounting bolt 4 M8-1.25 x 16 mm
12 Belt tensioner bracket 1
13 Flat-headed mounting bolt 2 M8-1.25 x 25
14 Belt tensioner 1
15 Hexagonal mounting bolt 1 MIO-I .5 x 61.86 mm
16 Belt, V-ribbed 1 Length 0.1524 mm
13-398
0
DISASSEMBLY AND ASSEMBLY BELT TENSIONER
REPLACEMENT OF BELT
3/84nch square head
Raise the tensioner and remove the belt.
Caution:The belt tensioner is a spring type, so

separate it from the drive belt and rotate
it. If the direction of rotation is mistaken,
the belt tensioner may be damaged.
fa9blma
REPLACEMENT OF BELT
TENSIONER
Preparatory work:
l Remove the belt.
15 mm
Remove the mounting bolts, then replace the
tensioner.
w: 43 Nm (4.4 kgm}
INSPECTION
Check that there is no excessive wear and enlarge-
ment of the hole at the tensioner pivot tube por-
0a
tion. If the tensioner is excessively worn, replace
it.
Rotate the bearing and check that there is no rough

portion and that it rotates freely.
f n9OOsa
13-399
0
DISASSEMBLY AND ASSEMBLY THERMOSTAT
Check that the thermostat works properly. 1

Condition
Start of actuation: 83 “C
Fully open: 95 “C
13-403
0
DISASSEMBLY AND ASSEMBLY FAN,COOLANT
FAN
A WARNING: Never pull the fan, twist it open,
or use it to rotate the engine.
Such action can lead to serious
personal injury and to damage
to the fan. Use only the correct
engine barring technology to
rotate the engine by hand.
A Caution: Never change the angle of the

blade to increase the air flow
(never bend the blade). If the
blade or spider are bent, there
will be stress generated in the
material used for the structure
of the fan. Changing the angle
(bending) the fan causes defec-
tive operation of the fan. Be sure
to select a fan of the correct di-
ameter. Never modify the exist-
ing fan.
COOLANT
Drain
Caution: Wait for the temperature to go down to
50 “C before removing the pressure cap A
from the cooling system.
If this is not done, boiling water may spurt out and

cause serious burns.
When draining the coolant, open the drain valve in
the radiator and remove the plug at the bottom of
the water take-off port. Generally speaking, a 20
liter (4 U.S. gallons) container is large enough to
catch the coolant.
13-404
0
DISASSEMBLY AND ASSEMBLY COOLANT
Check the hoses for damage, looseness, or dam-

aged clamps, and replace if necessary. Check for
leakage from the radiator, damage, and accumula-
tion of dirt, and clean or repair if necessary.
FILLING WITH WATER

60% 60%
Caution: Never use only water as the coolant. If
WATER WATER
only water is used, it will cause corrosion,
and this will result in damage.
A 50% 60%
ANTIFREEZE ANTIFREEZE
Caution:When adding cooling water, prepare a
50:50 mixture of anti-freeze and water
before starting. Anti-freeze does not have
the same capacity as water to remove the
heat from the engine, so if anti-freeze is
added to the engine first, the engine will
overheat before the water and anti-freeze
have mixed completely.
Close all the drain valves and add water. A 50:50

mix of water and ethylene glycol anti-freeze will
give protection in temperatures down to -36 “C.
Coolant capacity Liters

(engine only) (U.S. quarts)
B3.9 B5.9
483.9 6B5.9
4BT3.9 4BTA3.9 6BT5.9 6BTA5.9
7.Of7.41 9.7f10.31 10.5{11.1) 14.5U5.3)
Install the pressure cap. Run the engine to raise

the temperature to 80 “C then check for leakage of
coolant.
Check the coolant level again to confirm that the
radiator is full.
Caution: Wait for the temperature to go down to

50 “C before removing the pressure cap
from the cooling system. If this is not
done, boiling water may spurt out and
cause serious burns.
DISASSEMBLY AND ASSEMBLY ACCESSORY DRIVE ADAPTER
ACCESSORY DRIVE ADAPTER

c19009c
Index No. Part Name WtY Remarks
1 Accesson/ drive adapter 1

2 Bearing 1
3 Accessory drive shaft 1
4 Accessory drive gear 1
5 PTO drive cover gasket 1
7 PTO drive cover gasket 1
8 PTO drive cover plate 1
13-406
0
CLEANING
Wash the accessory drive with detergent, then dry
q\
INSPECTION
Checkvisuallyforcracks,
threads.
broken teeth, or damaged
0*
I cl9aesd
0s
Rotate the gear and check for rough portions or
excessive wear of the bearing.
cl9sesb
DISASSEMBLY
1.25inch pipe connector
Support the housing and push out the bearing, •l
shaft, and gear assembly.
A force of approx. 4 tons is required.
13-407
0
l-inch drift
Push the shaft and bearing out from the gear.
l-inch drift
RI
Support the bearing assembly and push out the
shaft.
Q
6%
ASSEMBLY
1.25-inch pipe connector
Support the inner race of the new bearing, then

push in the shaft until the shaft contacts the bot-
tom of the inner race.
2-inch pipe
Caution: Push the outer race of the bearing assem-

bly. If the inner race is pushed, the bear- ,+
ing will be damaged. @@
Support the housing and push in the bearing and
shaft assembly until it contacts the bottom. A
cl9shaa
13-408
0
1.25~inch pipe connector
Support the bottom of the shaft with a 1.25-inch

pipe connector, then push in until the gear con-
tacts the bottom of the inner bearing race.
Power steering adapter
Check the adapter, if there is any damage,

it.
replace
0
@
Measure the clearance at the crankshaft end of the

single-cylinder air compressor.
Clearance at crankshaft end

mm
0.05 Min
0.15 Max
I cpQshna 1
13-409
0
DISASSEMBLY OF UNLOADER
VALVE, CYLINDER HEAD
l-1/4 inch
Remove the following parts. l3l
l
l
Unloader cover (I)
Copper washer (2)
Unloader pin (4)
6x
Q
l Spring (5)
Dispose of the copper washer.

cp9hdma
Remove the O-ring (3) and dispose of it.

c%
Q
cp9arma
9/16 inch
Remove 4 cylinder head mounting bolts (6).
Remove cylinder head (7).
Remove cylinder head gasket (8) and dispose of it.
Operating hint: Make marks to indicate the correct

direction of the head before remov-
ing.
:p9csma
Socket (795-799-1330) or 3/4-inch hexagon

wrench
Set the bottom of the head at the top and install in
a soft jaw vice.
Remove exhaust valve seat (9).
13-410
0
Remove the following parts.
l
Exhaust valve disc (IO)
Spring (11)
68
Q #I
11
l Copper washer (2)
Dispose of the copper washer. q2

Caution: Push the exhaust valve stop securely and
do not remove it.
cr89spma
Socket (795-799-1330)
Remove intake valve cage (12). RI

6%
Q
OOmc
Remove the following parts.
l
Spring (11)
make valve disc (IO)
63
Q
l Intake valve seat (13)
l Copper washer (2)
Dispose of the copper washer.
Swama
CLEANING
A
Warning: When using any solvent, acid agent, or
alkaline agent for washing, follow the in-
struction from the manufacturer. Wear
protective glasses and protective cloth-
ing.
\
q
Soak the parts in carbon removal petroleum emul-
sion cleaning agent. Set the cleaning agent to a
pH value of less than 9.5 to prevent the aluminium
parts from turning black. For details of the con-
centration and temperature of the solvent and the
immersion time, please contact the manufacturer
or seller of the cleaning agent. cD9OOeb
Caution: When removing the carbon or scale, do

not use a scraper. It will damage the seal
surface.
Clean the parts with a stiff non-metal brush.
INSPECTION
Valve disc
Check the disc, and if there are any cracks exceed-

ing 0.13 mm, or holes or grooves, replace the disc.
a3
0
cp900sb
Intake valve seat
0a
Measure the distance between the valve seat con-
tact surface and the valve gauge contact surface.
Intake valve seat

mm
0.597 Min.
0.673 Max.
If the seat exceeds the limit or there are cracks or

damage, replace the valve seat.
Exhaust valve seat
Check the seat for damage and wear.
CPQOOSC
13-412
0
Measure the diameter of the valve guide.
Valve guide diameter

mm
@@ 1
25.53 Min
25.65 Max
Replace if the exhaust valve seat exceeds the limit.
cplauna
Measure the distance between the head of the valve

seat and the valve seat surface.
Valve seat diameter

mm
4.01 Min
4.11 Max
Replace if the exhaust valve seat exceeds the limit.
cp9OOna
Intake valve cage I

Check the cage for damage and wear.
03%
cP9OOsd
Measure the valve guide diameter.
Valve guide diameter

mm
25.53 Min
25.65 Max
Replace if the inlet valve cage exceeds the limit.
cP9sunb
Measure the distance from the head of the cage to

the valve stop.
Height of stop
mm
3.63 Min
3.78 Max
cp9OOnb
Exhaust valve stop
0a?
Check the exhaust valve stop. If the stop is loose
or damaged, replace the cylinder head assembly.
CPSOOse
Measure the distance from the valve end of the stop

to the surface of the cylinder head.
Height of stop
mm
4.42 Min
4.70 Max
Replace the cylinder head if the head exceeds the

limit.
cp900nc
032
Unloader pin
Check for damage and holes
13-414
0
Measure the pin length.
a
Pin length
mm
40.51 Min
40.72 Max
Replace if the pin exceeds the limit.
cP9Pina
Valve spring
Check the spring with a spring tester (795-790-

2100). Replace if it exceeds the limit shown in Table 08
1 below.
Caution: We recommend that you install a new
spring when reassembling.
CD8SPta
Table 1: Spring data

Force needed to compress spring to length
length Min Max
mm Kg Kg
Intake valve 5.08 0.272 0.340
Unloader 10.0230 1.90
Exhaust valve 5.08 0.272 0.340
Cylinder head
Check the thread, and replace if there
cracks, chips, grooves, or other damage.
Check the unloader seal bore for damage and holes.

Replace if there is any damage to the cylinder head.
cp9nahc
ASSEMBLY
Set the bottom of the cylinder head at the top, and
install in a soft jaw vice.
Install the following parts.
a. New washer
b. Intake valve seat
c. Intake valve
d. Intake valve spring
9ra ha
Socket (795-799-1330) and torque wrench

Tighten the cage.
w: 108 Nm Ill.0 kgm}
a. New washer
b. Intake valve spring
c. Intake valve disc
13-416
0
Socket (795-799-13301 or 314 inch hexagon

wrench and torque wrench
Tighten the seat.
m: 108 Nm III.0 kgm}
Install a new gasket and cylinder head to the block,

and align the match marks.
Install the 4 mounting bolts.
cD9csha
9/16 inch and torque wrench
Install the mounting bolts. RI-
-: 30 Nm 13.1 kgm} ab
@@
0K
Tighten the bolts again in the order shown in the
w:
diagram.
41 Nm I4.2 kgm}
Install a new O-ring to the unloader pin.

l-1/4 inch and torque wrench
a. Spring
b. Unloader pin
c. New washer
d. Unloader cover
Tighten the cover.
m: 41 Nm I4.2 kgm}
cp9sphb
Warning: To prevent personal injury or property . I
damage, the air discharge line must be A

able to withstand high temperature and
high pressure. Follow the instructions
from the manufacturer.
Check for carbon deposits at the air discharge line 032

connections to the No. 1 tank or the wet tank.
If the carbon deposit is thicker than 1.6 mm IO.061,
clean or replace the line and fitting. For details of
the method of cleaning or replacing, see the in- , -
G=J
Install and tighten the intake and exhaust connec-

tions.
Torque value
Inlet port 5 Nm IO.51 kgm)

*Outlet port 24 Nm (2.4 kgm}
* There is a l/2 NPT fitting at the head.
Caution: The torque for the discharge line differs

according to the size and type of the line.
For details of the correct torque, contact
the machine manufacturer.
Close the wet tank drain valve.

Start the engine and check for leakage of air.
13-418
0
REPLACEMENT OF AIR COMPRESSOR

Preparatory work:
l Clean the air compressor with steam, then
dry with compressed air.
l If there is a water-cooled cylinder head in-
stalled to the compressor, drain the engine
coolant. If the air compressor is air cooled,
there is no need to drain the engine coolant.
l Open the wet tank drain valve and release
the air from the line.
After releasing the pressure, close the drain
valve.
REMOVAL
Remove the air connector from the air compres-
sor.
15116 inch, 718 inch
Remove the coolant line from the air compressor

(this does not apply to air-cooled compressors).
9/16 inch
Remove the oil supply line.
b
WI6 inch
Remove the oil return line from the bottom of the

air compressor.
- cp9tbma
18mm,14mm,10mm
Remove the air compressor support bracket and

mounting bolts.
Remove the air compressor mounting nuts.
Remove the air compressor.
INSPECTION
032
Check the compressor housing visually for cracks
or damage.
Check the drive gear visually for cracks or dam-
age.
cp9hssa
Check that the gear housing and air compressor

gasket surface is clean and not damaged.
a
,O
cp9hsst
i 3-420
0
POWER STEERING COUPLING (WHEN USED)
Check the coupling for wear or cracks.

If the coupling is damaged, replace it. 0a
cD9cPsa
Power steering adapter
Check the adapter and replace it if it is damaged.

0a
co9adsa
Air compressor timing

(single-cylinder air compressor)
Removethe unloadervalve or head and search for

the compressor crankshaft TDC position. (See the
air compressor manual.) The TDC position does
not have to be accurate. It can be slightly out of
adjustment.
cp9csha
Mark the TDC position (the 12 o’clock position as

seen from the front) on the air compressor gear
surface with ink or dychem.
cp9sewa
After determining the TDC position, check if the

timing pin is out of position.
Push the timing pin and slowly bar the crankshaft
0GE
to determine the TDC position of the No. 1 cylin-
der.
Rotate the compressor TDC mark 60” forward from

the TDC position or 6 teeth forward (if the gear has
36 teeth). This position becomes approximately
the 10 o’clock position as seen from the front of
the air compressor.
Caution:On the Holset air compressor series

SSQE120, 296, and 338, a radial line indi-
cating the TDC position is etched on the
gear.
cp9aewb
INSTALLATION I
18mm,14mm,10mm
Fit a new gasket and install the air compressor to

the gear housing.
Install the air compressor support bracket.
%nting nut : 77 Nm I7.9 kgm)

Support mounting bolts : 24 Nm 12.4 kgml
Caution: The gear timing is unnecessary.
9/16 inch
Install the oil supply line.
w: 15 Nm Il.5 kgm}
13-422
0
15 mm
Install the oil drain to the bottom of the compres-

sor.
m: 24 Nm (2.4 kgm)
-
cP9tbhc
15/16 inch, 7/8 inch
Caution: When using a rubber grommet in the

q
cooling or air line, if the grommet is worn
or damaged, it will cause leakage, so in-
stall it carefully.
Install the coolant line.
m: 24 Nm (2.4 kgm)
\ \\ k&?i-/m-h ccstbhc
Install the air line.
0a
Fill the engine cooling system (water-cooled air
compressor).
Start the engine and check for leakage.
13-423
0
Start the engine, then start the air compressor.

Set the air compressor pumping to 5.6 - 7.0 kgm
and use soapy water to check for leakage of air.

Remove the gasket material from the seal surface.

tive clothing, safety glasses, and face A
burns.
Caution: Cover all the openings with tape to pre-

vent the detergent or steam from enter- A
ing the oil passage in the air compressor
and causing damage.
Clean the air compressor with detergent

then dry with compressed air.
or steam, q
\
INSPECTION
Checkthe compressor gear drive visually for cracks
0a
or broken teeth.
Check the compressor housing visually for cracks
or damage.
Check the fuel pump drive hub or spider joint for
wear or damage.
13-424
0
ACCESSORY DRIVE ADAPTER
DISASSEMBLY AND ASSEMBLY ALTERNATOR
Power steering joint (if used)
032
Check the joint for wear or cracks.
If there is any damage, replace the joint.
cP9cPsa
ALTERNATOR
REPLACEMENT OF ALTERNATOR
Preparatory work:
l Remove the ground cable from the battery
terminal.
l Remove the drive belt from the alternator
pulley.
z
RI
%
6
11 mm
Remove the wire, fit a tag, then do as follows. c%
Q vh
13 mm
Remove the alternator link mounting bolts.
16 mm
Remove the alternator mounting bolts. RI

CE
Q
i9csme
13-425
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR, STARTING MOTOR
When assembling the alternator, loosen or tighten

the alternator mounting components in thefollow-
ing order.
1. Alternator bracket mounting bolts for alterna-

tor
2. Alternator mounting bolts for bottom brace
3. Cooling water inlet port mounting bolts for al-
ternator
4. Block mounting bolts for cooling water inlet
Poe
Caution: The wrench size and tightening torque is
determined by the alternator manufac-
turer and model. For details of the tight-
ening torque, see the engine component
section.
INSPECTION
Check the alternator visually for damage and the
housing for cracks and other damage. Check also
for damage to the fan blade or pulley and wear of
the mounting holes in the alternator end frame.
ee9OOka
STARTING MOTOR
REPLACEMENT OF STARTING MOTOR
Preparatory work: RI
Remove the ground cable from the battery
terminal. 6%
Q
Distinguish each wire with a tag to show its
position.
17 mm
Remove the battery cable from the solenoid.
10 mm
Remove the starting motor

Install the starting motor in the reverse order to
removal.
w: 43 Nm 14.4 kgm1
13-426
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
INSPECTION
Check gear (I) visually for cracks and broken teeth.
Check drive bushing (2) and gear shaft (3) visually
for excessive wear or damage.
Check terminal post (4) visually for looseness or
broken connection portion.
Caution: If the starting motor parts are damaged

or the post is loose or damaged, repair
the starting motor or reassemble it. When
assembling the starting motor, see the
specifications of the electrical component
manufacturer.
REPLACE HYDRAULIC SWITCH

Remove the wire from the transmission unit.
Caution:The transmission unit shown in the dia-

gram may be different from the unit in-
stalled by the component manufacturer.
Connect the wire to the transmission unit.
0K
(when installed to cast iron) 16 Nm Il.6 kgm}
(when installed to aluminium) 10 Nm Il.0 kgm}
REPLACEMENT OF WATER TEMPERA-

TURE SENSOR
Preparatory work:
l Drain the cooling water.
10 mm or screwdriver RI
Remove the wiring from the temperature sensor.
BQ
13-427
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
22 mm
Remove the temperature sensor. RI
CE
Q
22 mm
When installing the temperature sensor, coat the •l

thread with liquid Teflon sealant.
@I($
Connect the wiring.
&@
m:
(when installed
(when installed
to cast iron)
to aluminium)
50 Nm i5.1 kgm}
30 Nm 13.1 kgm} 0q
13-428
0
15 REPAIR AND REPLACEMENT OF
PARTS
Outline .......................................................... 15- 2 Method of grinding valve seat .................... 15-13

Repair guideline ...................................... 15- 2 Method of installing valve seat ................... 15-17
When should substitute repairs be Machining exhaust valve insert pocket ...... 15-17
carried out ........................................... 15- 2 Replacing valve seat ................................ 15-20
Inspection ................................................ 15- 2 Method of grinding valve ............................ 15-21
To ensure safety, follow all Checking tension of valve spring ........... 15-22
instructions in manual ........................ 15- 2 Assembly of cylinder head ......................... 15-23
Follow washing methods given Procedure for repairing cylinder block ....... 15-24
in manual ............................................. 15- 2 Repair tools .............................................. 15-24
Follow inspection methods Combustion deck ..................................... 15-24
given in manual ................................... 15- 2 Cam bore .................................................. 15-25
Repair methods for screws using Outline of repair of cylinder bore ........... 15-26
coil thread insert ...................................... 15- 3 Cylinder bore ........................................... 15-26
Method for using taper thread plugs to seal Installation of repair sleeve .................... 15-28
pockets and small holes in castings ...... 15- 4 Procedure for repairing crankshaft ............. 15-32
Repair procedure ..................................... 15- 4 Repair tools .............................................. 15-32
Method for repairing taper thread Outline of grinding crankshaft ................ 15-32
plug holes worn by large size Regrinding specifications for
copper plated plugs ................................ 15- 7 crankshaft journal ............................... 15-33
Method of using filler metal in emergency Regrinding crankshaft journal radius ..... 15-34
repairs ...................................................... 15- 8 Specification for regrinding crankshaft
Procedure and tools for repairing rod journal ........................................... 15-35
cylinder block .......................................... 15- 9 Regrinding crankshaft rod journal
Inspection and grinding to repair radius ................................................... 15-35
combustion deck ..................................... 15- 9 Optional procedure ................................. 15-36
Inspection and installation of valve Procedure for repairing connecting rod ..... 15-37
guide ........................................................ 15-10 Installation of pin bore bushing ............. 15-39
Procedure 1 for building up using Machining of connecting rod bushing ... 15-41
service valve guide .................................. 15-11 Inspection of curvature and twisting
Procedure 2 for building up using of connecting rod ................................ 15-42
service valve guide .................................. 15-12 Testing alignment of connecting rod ..... 15-43
Outline of valve seat repair ......................... 15-12 Inspection of twisting of
Calculating grinding depth of valve connecting rod .................................... 15-43
seat ........................................................... 15-13 Replacing valve seat insert ..................... 15-44
Packing style of cylinder head and
how to install plugs .............................. 15-47
102 SERIES 15-1

8
REPAIR AND REPLACEMENT OF PARTS OUTLINE
OUTLINE
REPAIR GUIDELINE TO ENSURE SAFETY, FOLLOW ALL
INSTRUCTIONS IN MANUAL
The 102 engine uses the latest diesel technology,
but it is designed to make it possible for repairs to For cleaning solvents and other substances used
be carried out at a high level of quality using exist- during repair of the engine, always keep to the rec-
ing repair practices. ommendations of the manufacturer. With regard
to tools and maintenance facilities, always observe
WHEN SHOULD SUBSTITUTE REPAIRS practices that ensure complete safety.
BE CARRIED OUT
FOLLOW WASHING METHODS GIVEN
In the following explanation of the procedures, IN MANUAL
mention is also made of a separate repair method
to use instead of large-scale replacement of engine When repairs have been completed, check that all
parts. The decision is governed by various condi- metal particles produced by the machining have
tions, such as technical demands, possibility of been completely removed and that the applicable
use, cost, and considerations related to the length parts have been completely cleaned.
of the downtime of the equipment.
FOLLOW INSPECTION METHODS GIVEN
INSPECTION IN MANUAL
This procedure manual assumed that the compo- After completing repairs, carry out the necessary
nent parts have already been checked, and that the inspections to check that the applicable parts fulfill
points which do not match the standard have been the technological requirements needed to with-
checked during repair or overhaul. This manual stand future continued use as an engine compo-
covers only inspection requirements related di- nent.
rectly to the alternative repair procedures.
15-2 102 SERIES

REPAIR METHODS FOR SCREWS USING
REPAIR AND REPLACEMENT OF PARTS COIL THREAD INSERT
REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT

The 102 engine uses metric cap screws.
1’ i‘- LLengthinmm
Distance
Main thread diameter
between
in mm
threads in mm
The coil insert is a precision made thread repair liner made of stainless steel wire in a coil shape. These
coils are designed so that the diameter becomes larger than the stepped hole when they are not ma-
chined. After an insert is installed, it expands to the outer wall of the stepped hole. When the insert
expands in this way it becomes fixed in position.
The standard insert is made of stainless steel wire, but other materials can also be used in order to fulfill
special requirements.
Only four steps are needed to repair the thread by this method: making holes, steps, peeling off tang, and
removal. In parts using thin wall surface material, the insert can be used to restore any damaged or
broken thread to its original size. One more advantage of these inserts is that they do not wear even with
repeated use.
15-3
METHOD FOR USING TAPER THREAD PLUGS TO
REPAIR AND REPLACEMENT OF PARTS SEAL POCKETS AND SMALL HOLES IN CASTINGS
METHOD FOR USING TAPER

THREAD PLUGS TO SEAL
POCKETS AND SMALL HOLES
IN CASTINGS
This explanation of the repair procedure is a guide-
line for the method of use of a taper thread plug to
repair slight defects which cause leakage in cast-
ings, such as pin holes, blow holes, and pocket of
dirt or slag or sand. These defects can be
repaired in the following cases.
1. Oil or water continues to leak out from the en-

gine.
2. The locations of the defect is at a place where

there is no strain on the casting, or in portions
where no other machining has been carried out.
A taper thread plug is also used for repairing cracks,

but the guideline for repairs of castings with cracks
is not included here.
This method cannot be used for carrying out re-

pairs in the following places.
1. Oil passage boss.
2. Cast portions in positions where a drilled hole

or mounted taper thread plug would interfere
with the operation of the engine or any of the
engine components.
3. The wall portion of the casting between the wa-

ter passage and oil passage.
4. The boss of the cylinder head cap screw.
A taper thread plug can be used for repairing cast-

ings in the following cases.
1. Defects which can be removed with a tap drill.
2. Places where the necessary plug size is a maxi-

mum of 27.53 mm (1.084 in).
3. Places with defects where the maximum thick-

ness of the wall is at least 3.97 mm (5/32 in).
REPAIR PROCEDURE
There is a special tap drill size and tap size for each
size of taper thread plug. Check that you are using
the correct size of tap drill and tap to match the
size of the taper thread plug.
15-4
lronite X Y Cummins
Part Diameter at Thread Drill lronite tap
No. small end length size tap No. Part No.
mm mm
210200 5.08 3.8 II/64 530200 555228

210235 5.97 23.8 13164 530235 555229
210237 8.32 36.5 5116 530237 555230
210420 10.67 25.4 25164 530420 555231
210421 10.67 36.5 25164 530420 555232
210490 12.45 25.4 15132 530490 555234
210491 12.45 36.5 15132 530590 555234
210590 14.99 25.4 23132 530780 555236
260780 19.81 25.4 23132 530780 555236
261080 27.53 25.4 1.00 531080 555237
A: Standard pipe plug
B: Taper threaded plug
B
102E2370
1. Using a portable disc grinder or wire brush, re- ameter of the hole is 25.4 mm.
move all paint and rust from the defective area.
Caution: The thickness of the wall of the casting at
Caution: If repair is carried out with the engine still the problem point must be at least 3.97
installed to the machine, be careful not to mm {5/32 in}.
let any chips or particles enter the engine.
4. Use the correct size of taper to cut the thread
2. Make a hole with the correct size of tap drill to in the hole. A minimum of at least four com-
match the plug that is used. Make sure that plete threads is necessary to seal the plug. Be
the size of the drill bit is large enough to com- sure to remove all chips and particles after
pletely remove the problem area. Do not use a grinding.
drill bit that is larger than necessary. After
5. Coat the plug thread with LoctiteTM 601 ST-1272-
making the hole, remove all the chips and par-
12 LoctiteTM compound or the equivalent.
ticles.
6. Insert the plug and tighten it.
3. Check the hole made by the drill. If there is
any problem with the wall of the hole, make a 7. Using a metal saw, cut off the plug. Leave at
hole for the next largest plug. Repeat this pro- least 0.794 mm of the plug from the surface.
cedure until there is a hole with no defects in
the wall. Do not forget that the maximum di-
15-5
8. Using a small ball peen hammer flatten the pro-

truding portion of the plug. Flatten the plug so
that the top thread of the plug seals the top
thread of the hole.
9. Leave for at least 30 minutes for the LoctiteTM
sealant to harden.
10. Using a hand grinder or file, make the top of
the plug level with the surface of the casting.
Caution: If repairs have been carried out to the
water passage or oil passage wall surface,
the plug must be tested with an air pres-
sure of 345 kPa (3.5 kg/cm*}. Apply pres-
sure to the passage and coat the top of
the plug with soapy water to check that
no bubbles are formed. If bubbles are
formed, it means that the leakage has not
been properly repaired. Start again from
Step 2 of the above procedure an’d install
the next size of taper thread plug.
11. If necessary, paint the repaired portion with
paint of a matching color.
15-6
METHOD FOR REPAIRING TAPER THREAD PLUG HOLES
REPAIR AND REPLACEMENT OF PARTS WORN BY LARGE SIZE COPPER PLATED PLUGS
METHOD FOR REPAIRING

TAPER THREAD PLUG HOLES
WORN BY LARGE SIZE COP-
PER PLATED PLUGS
It is possible to repair a worn taper thread plug
hole using the following method.
l Clean the thread portion with trichloroeth-

ylene Ill or the equivalent.
l Fit the correct size of pipe tap to the thread.
l Install a copper plated (large size) taper

thread plug using taper thread plug sealant.
15-7
METHOD OF USING FILLER METAL
REPAIR AND REPLACEMENT OF PARTS IN EMERGENCY REPAIRS
METHOD OF USING FILLER

METAL IN EMERGENCY RE-
PAIRS
The explanation for this procedure gives informa-
tion regarding the method of use of compound filler
metal in emergency repairs.
Repair methods using filler metal must not be used

as a substitute for permanent repair or replacement
of parts.
Filler metal can be used to provide temporary limi-

tation of permeation, adjustment of the surface, or
cover for chipped parts.
g WARNING:
Do not attempt to use this method for repair
of components or parts related to safety.
It is possible to obtain metal filler based on vari-

ous metals, such as iron, brass, or aluminium.
Check that the filler metal matches the material of
the part being repaired. The filler metal must have
the same resistance to temperature, stress, and
pressure as the material of the part being repaired.
Metal filler compounds have many purposes: some

can be used to join different types of metals, while
others cannot be used for such purposes. To
achieve a good result, follow the recommendations
of the manufacturer.
15-8
PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK
REPAIR AND REPLACEMENT OF PARTS INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK
PROCEDURE AND TOOLS FOR

REPAIRING CYLINDER BLOCK
Valve refacer
Valve seat grinding machine
Valve guide installation tool
INSPECTION AND GRINDING

TO REPAIR COMBUSTION
DECK
Check the head surface and look for chipped or
scratched places and corrosion
Check that there is no deformation of the head as
0a
Limit
Variation value: 0.010 mm (0.0004 in) for area of

any radius of 50.8 mm (2.0 in) (B
The limit for the overall variation value from one
edge to the other edge is as shown below.
0.20 mm - 4-cylinder engine

0.30 mm - g-cylinder engine I kn900tb
Remove any dirt from the surface of the combus-

tion deck. If there is any need to maintain the sur- A = Total 1 .OO mm
face smoothness or the repair limit for flatness, it
B = Min. 94.00+0.25 mm (given only for reference)
is possible to grind the desired amount provided
the amount that is ground does not exceed a total C = Surface finishing 1.5 to 3.2 micrometres
of 1.00 mm. Each amount of grinding must be dis-
D = Location to display amount of grinding with
played with a steel stamp at the bottom right cor-
stamp
ner of the rear face immediately above the edge of
the combustion deck.
102E2372
15-9
REPAIR AND REPLACEMENT OF PARTS INSPECTION AND INSTALLATION OF VALVE GUIDE
INSPECTION AND INSTALLA-

TION OF VALVE GUIDE r
Check the valve guide to see if it scratched or dam-
aged.
Limit
Diameter: 8.039 mm
If inspection shows that the valve guide bore is

102E2373
worn, the valve head must be machined and a ser-
vice valve guide installed. After the valve guide is
installed to the head, it must be finished by ream-
ing.
Caution: After inspection, if it is judged that a ser-

vice valve guide and valve insert are required, in-
stall the service guide first.
Valve guide Part No.
Komatsu Part No. - Intake (thick wall)

6736-19-1310
Komatsu Part No. - Exhaust (thick wall)

6736-19-1410
Komatsu Part No. - Intake (thin wall)

6736-18-1310
M-10
PROCEDURE 1 FOR BUILDING UP USING
REPAIR AND REPLACEMENT OF PARTS SERVICE VALVE GUIDE
PROCEDURE 1 FOR BUILDING

UP USING SERVICE VALVE
GUIDE
6736-18-1310
Machine the valve guide bore of the cylinder head
base material to dimension A.
A = Diameter 11.12M0.013 mm
I
Carry out centering with the valve seat to a diam-
eter of within 0.35 mm, and set at right angles to
the combustion face within 0.10 mm at a radius of
50.0 mm. 102E2374
Install the valve guide as shown in the diagram.

A = Lubricate with oil and push the guide so that it
is level with the bottom of the boss.
B = 12.00 + 0.75 mm (Reference)
C = If necessary, grind until it is level with the top

of the guide boss.
D = 8.029+0.010 mm
Caution: Forthe final bore after assembly, carry out '02E2375
centering with the valve seat to a diam-
eter of within 0.35 mm. It must be at right
0s
angles to the combustion face within 0.10
mm at a radius of 50.0 mm.
After completion of assembly, touch the valve stem

and check that the collet is fixed in position.
kn9vawd
15-11
PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE
REPAIR AND REPLACEMENT OF PARTS GUIDE, OUTLINE OF VALVE SEAT REPAIR
PROCEDURE 2 FOR BUILDING

UP USING SERVICE VALVE
GUIDE
6736-19-1310 and 6736-19-1410
Machine the valve guide bore of the cylinder head
base material to dimension A.
A = Diameter 14.00+0.013 mm
Carry out centering with the valve seat to a diam-

eter of within 0.35 mm, and set at right angles to
the combustion face within 0.10 mm at a radius of
50.0 mm.
Install the valve guide as shown in the diagram.
Lubricate with oil and push in the guide so that it

protrudes dimension A from the cylinder head.
Carry out reaming to finish the bore to dimension

B.
A = 12.25rtO.50 mm
B = 8.029+0.010 mm
102E2378
OUTLINE OF VALVE SEAT RE-
There is a valve seat assembled to the cylinder

head. It is possible to regrind the seat only once.
If any seat has been previously reground, the seat
must be replaced with a service seat.
After regrinding the seat, mark it with an X.
To indicate that a service seat has been installed,

stamp the head with two Xs.
It is possible to regrind the service seat only once.

For details, see the section on the method for grind-
ing the seat.
A kn9OOvf
15-12
CALCULATING GRINDING DEPTH OF VALVE SEATS
REPAIR AND REPLACEMENT OF PARTS METHOD OF GRINDING VALVE SEAT
CALCULATING GRINDING
DEPTH OF VALVE SEAT
Install the valve to the specified position, then
measure the depth of the valve.
kn9vans
The depth of the valve is the distance from the valve

face to the head deck.
Note the measurement for depth @ of each valve.
I c
METHOD OF GRINDING
VALVE SEAT
Grind the valve seat to remove any scratches or
heat damage.
Seat angle
Intake valve: 30”
Exhaust valve: 45”

Install the valves to the respective bores, then mea-

sure the depth again.
kngvano
Note the measurement for depth @ of each valve.
Calculate so that the ground depth (GD) is as fol-

lows.
GD - (B) - (A)
Limit
GD: 0.254 mm
102E2387
After grinding the valve seats, stamp the distin-

guishing mark on them.
15-14
Install the valves to the specified position, then

measure the depth.
kn9vana
Check depth @ of the valve.
Limit
Depth: 0.99 mm - 1.52 mm
If the depth exceeds the limit, replace the valve.
Coat each valve lightly with valve lapping com-

pound, then fit a barto each valve and rub the valve
until it fits.
Remove the valve and wipe off all the lapping com-
pound from the valve and seat.
I kn9vaec
Measure the width of the valve seat to the lapped

surface.
Limit for valve seat width
Min. value 1: 1.5 mm
kn9vanm
If necessary, grind area @ with a 60” grindstone

and area @I with a 15” grindstone, then center the
seat and valve face. Be sure to keep the valve seat
width within the limit.
kn9vano
15-16
METHOD OF INSTALLING VALVE SEAT
REPAIR AND REPLACEMENT OF PARTS MACHINING EXHAUST VALVE INSERT POCKET
METHOD OF INSTALLING
VALVE SEAT tion on the valve guide. If it is necessary to
install the valve guide, install the valve guide
When installing a seat to a cylinder head without a
before installing the service seat.
valve seat, it is necessary to modify as follows.
A = 8.029+0.010 mm
For cylinder heads with a valve seat, measure the
dimensions of the valve seat pocket. If it is outside C = 10.40f0.10 mm
the following dimensions, it is necessary to replace D = Diameter 47.00f0.013 mm
the cylinder head.
E = Max. radius 0.40 mm
Machining intake valve seat pocket
F = Surface finishing 3.2 micrometres
(Valve seat part number: 6732-l l-l 180)
Inspect the valve guide bore according to the sec-
f hU
102E2395
MACHINING EXHAUST VALVE A= 8~~~~f~~~~~

mm
INSERT POCKET C = 10.20f0.10 mm
Valve seat part number: 6732-11-1170 D = Diameter 43.650f0.013 mm
E = Max. radius 0.40 mm
Surface finishing 3.2 micrometre
102E2396
15-17
-
Staking tool
I
p-__
Push the valve seat into the valve seat pocket. For RI I ?
details of the current valve seat part number, see

@I/$
I ;-':
the parts. i--__
L+
@@
--
Push the valve seat into the pocket.
q@
Grind the valve seat lightly to provide a suitable

seat angle.
kn9brxb
Seat angle
Intake valve: 30”
Install the valves to the specified position, then

measure the depth.
kn9vans
15-18
Check depth (C) of the valve.
Limit
Depth: 0199 mm - 1.52 mm
Coat each valve lightly with valve lapping com-

pound, then fit a bar to each valve and rub the valve
until it fits.
Remove the valve, and wipe off all the lapping com-
pound from the valve and seat. Q
Gx
q
\
kn9vaec
Measure the width of the valve seat to the lapped

surface.
Limit for valve seat width

I kn9vanm
15-19
If necessary, grind area @ with a 60” grindstone

and area @ with a 15” grindstone, then center the
seat and valve face. Be sure to keep the valve seat
width within the limit.
REPLACING VALVE SEAT

kn9vano
Special tools required
No. Part No. Part Name o’ty 1. Removing valve seat insert
A 795-100-4801 Puller (valve seat) I A Before carrying out the grinding operation, test
run the grinder for 1 minute to check that there
1
B 795-744-l 110 Pfuo;?&ykje valveI is no abnormality.
. If the grindstone has been replaced, test run
c 795-744-l 120 ,‘f”,;hFh”,l, valve) I for 3 minutes.
Check that the grindstone is not damaged, in-

795-100-3005 Seat cutter (kit) 1 stall so that there is no play in the grinder shaft,
795-100-3100 Body assembly 1 and use safety glasses when using the grinder.
l z
z?
795-100-3200 l Micrometer 1
1
795-100-3300 l Gauge 1
1 795-100-3401 1*Tool head 1 1
D :,,i,rr,
II 4 7g5-100-3750
Cutter
(for exhaust valve)
1
795-100-4731 Pilot (08.01) 1
5 795-100-4741 Pilot (08.02) 1
795-100-4751 Pilot (08.03) 1
l When using the valve seat puller to remove the

valve seat
1) Install grindstone @to grinder 0.
2) Align the groove of sleeve @ with holder

0, then insert.
Ir Adjust the position of the grinder with

set screw 0.
I 6162F504
15-20
REPAIR AND REPLACEMENT OF PARTS METHOD OF GRINDING VALVE
METHOD OF GRINDING
0+a
VALVE
inspect to check that there is no abnormal wear at
any place on the head or stem.
w
Limit
Min. value for diameter: 7.935 mm
kn9vata
Grind all reused valves to correct them. Checkthat

there are no bent valves. Replace any bent valve. 0
a
Seat angle
Intake valve: 30”
Measure the rim thickness.
Limit
Min. value IT): 0.79 mm
15-21
REPAIR AND REPLACEMENT OF PARTS ASSEMBLY OF THE CYLINDER HEAD
ASSEMBLY OF CYLINDER
HEAD
Caution: Before starting assembly, make sure that
the component parts of the cylinder head are clean.
\
q
Install the valve stem seal.
The seal for the intake and exhaust sides is differ-

ent.
kn9seha
Lubricate the stem with engine oil, then install the

valve.
Assemble the spring and retainer, then compress

the valve spring.
kn9sphd
Install a new valve collet, then release the spring

tension.
15-23
REPAIR AND REPLACEMENT OF PARTS PROCEDURE FOR REPAIRING CYLINDER BLOCK
PROCEDURE FOR REPAIRING

CYLINDER BLOCK
REPAIR TOOLS
Camshaft bore boring bar
Camshaft bearing driver
Cylinder boring bar
Cylinder block and head surface grinding machine

Cylinder honing set
Caution: It is possible to carry out the following

repair using standard gasoline automo-
bile tooling at a local automobile engine
repair shop.
COMBUSTION DECK
Simple straight edge and clearance straight edge
Using a simple straight edge and clearance straight
edge, measure the flatness of the whole block. The
flatness of the whole block, that is the flatness from
edge to edge and from side face to side face, must
not exceed 0.075 mm.
Check the combustion deck visually and check for

local dents or incomplete condition. If any such
places are found, that block deck must be reground.
It is possible to regrind the combustion deck up to
2 times. The initial amount of correction by grind-
ing shall be 0.25 mm.
If it is necessary to grind further, it is possible to

grind another 0.25 mm. The total permissible
amount of grinding is 0.50 mm.
A. 0.25 mm Amount to remove in

1st grinding
0.25 mm Amount to remove

in 2nd grinding
0.25 mm Total permissible

amount to remove 102E2419
in grinding
B. 323.00 mmfO.10 Standard
322.75 mm_+O. 10 Amount to remove in

1st grinding
322.50mm-I-0.10 Amount to remove

in 2nd grinding
Conditions for surface finishing =

1.5 - 3.2 micrometres
15-24
If the block has been ground 0.25 mm, an X must

be stamped at the top right corner at the rear face
of the block. If the block is ground a 2nd time and
the total amount removed in grinding is 0.50 mm,
a 2nd X must be stamped
beside the first X.
For details of a suitable head gasketto use together @

with the block after grinding, check the parts cata-
log. Be careful to ensure the correct clearance from
the piston to the valve.
102E2421
CAM BORE
It is possible to grind the front cam bushing bore
by the fairly large amount of 57.734kO.018. (The
intermediate and rear journal must not be ground
to the front journal oversize dimension.) The in-
termediate journal and rear journal can be ground
to a large 57.24WO.018 mm. The surface finishing
of 2.3 micrometres must be maintained. Any bore
can reach 3.2 micrometres, but the area must be
less than 20%.
Caution: The journals can be repaired individually.

To repair damaged journals individually,
there is no need to grind the bore of the
undamaged journal unnecessarily.
Install all the cam bushings so that they are level

or below the surface of the front journal. Align-
ment must be made so that a 3.2 mm rod can pass
freely through the oil hole.
The intermediate journal and rear journal cannot

be repaired using a standard front bushing. For
details of the correct oversize cam bushing, see the
parts book.
swd
15-25
OUTLINE OF REPAIR OF CYLINDER

BORE
The cylinder bore can be repaired in the following
two ways.
Method 1: Open a larger hole and use a larger pis-
ton and ring.
Method 2: Make a hole, install a repair sleeve, and

return the bore to the standard size.
Two types of oversize piston and ring
are available: 0.5 mm and 1.00 mm.
If the larger (I.00 mm) bore is needed,

it is necessary to use a repair sleeve.
Depending on the need, the sleeve can
be installed to individual cylinders. The
old repair sleeve can be removed from
the bore and replaced by using a bor-
ing bar. The cylinder bore must not be
cut in excess of the oversize limit.
CYLINDER BORE
Before it becomes necessary to use a repair sleeve
for the block cylinder bore, the hole can be made
again twice. The first time should be a large 0.50
mm.
When making the 2nd hole, it should be a large

1 .OO mm.
Diameters when making holes
A. 102.469 mm Diameter when making

1st new hole 102E2423
102.969 mm Diameter when making
2nd new hole
Dimension of honing
B. 102.02M0.020 mm Standard bore

102.520?0.020 mm Diameter when making
1st new hole
103.020&0.020 mm Diameter when making
2nd new hole
After making the hole, use a honing grindstone to

grind the edge of the bore to give dimension C.
C = Approx. 1.25 mm x 15”
15-26
REPAlR AND REPLACEMENT OF PARTS PROCEDURE FOR REPAIRING CYLINDER BLOCK
A surface which has been given correct honing will

have a cross-hatch pattern, and the angle of the
line will be 15 - 25” to the top surface of the cylin- Upper surface of cylinder block
der block.
Rough grinding: Use an 80 grit honing grindstone
Finishing grinding: Use a 280 grit honing grind-
stone
The surface finishing must be a maximum of 1.2
micrometres.
After completion of finishing
q
Wash the cylinder bore immediately with concen- \
trated washing solvent and hot water. After rins-
ing, apply a breeze to the block to dry it.
ck9breh
032
Check if the bore is clean by wiping it with a white
cloth soaked in diesel oil.
If the block is not to be used immediately, coat it
with rust prevention agent. 0e,
-
-- ck9bdwn
15-27
INSTALLATION OF REPAIR SLEEVE

t-A---i
Repair sleeve part number 6736-29-2110
If an oversize bore of more than diameter 1.00 mm

is needed, the hole must be made in the block again
and the repair sleeve installed. After installing, the
sleeve bore must be finished again to a diameter
of 102.020&0.020 mm. Use the standard diameter
piston and service piston ring set.
Making a new hole in block for repair sleeve
A = 104.515 + 0.015 mm 102E2427
104.500 - 0.000 mm
B = 6.35 mm
After completely making the hole, remove all metal
q
chips, particles, and oil completely from the bore, \
and install the repair sleeve.
Cool the repair sleeve at -12°C (+I 0°F) for at least

one hour. Remove the sleeves one at a time and
install them to the block as follows.
When installing the sleeve, coat each bore one at a

time with LoctiteTM620.
102E2429
Using protective gloves, push the frozen sleeves

as far as possible into the bore by hand.
15-28
Komatsu part number 3823230
Using a sleeve driver, push the sleeve in until it

contacts the step at the bottom of the bore.
102E2431
Set up the boring bar and machine to the follow-

ing dimensions.
A = 101.956 mm
B = Min. - level with block

Max. - protrudes 0.050 mm
After removing the boring bar, use a honing grind-

stone to grind the edge of the repair sleeve to di-
mension C.
C = Approx. 1.25 mm x 15”
102E2432
102 SERIES
15-29
A surface which has been given correct honing will

have a cross-hatch pattern, and the angle of the @@
line will be 15 - 25” to the top surface of the cylin-
der block. I Uucer surface of cvlinder block
Rough grinding: Use an 80 grit honing grindstone
Finishing grinding: Use a 280 grit honing grind-

stone
Finishing grinding dimension:
102.02+0.020 mm
The surface finishing must be a maximum of 1.2

micrometres.
After completion of finishing
Wash the cylinder bore immediately with concen-

trated washing solvent and hot water. After rins-
\
q
ing, apply a breeze to the block to dry it.
ck9breh
Check if the bore is clean by wiping it with a white

cloth soaked in diesel oil.
If the block is not to be used immediately, coat it

with rust prevention agent.
ck9bdwn
15-30 102 SERIES

@
REPAIR AND REPLACEMENT OF PARTS PROCEDURE FOR REPAIRING CONNECTING ROD
PROCEDURE FOR REPAIRING

CONNECTING ROD
REMOVAL OF PIN BORE BUSHING
The tools for removing and installing part number
3823902 connecting rod pin bore bushing are as
shown below.
Index No. Part No. Explanation w
1 3823903 Anvil
2 3823904 cup
3 3823905 Mandril i
4 3823906 Stop ring (thick) 1
5 3823907 Removal/installation 1
Ring (thin)
6 Hair pin cotter 1
7 3377676 Instruction manual 1
q$
Set the end of the connecting rod pin bore in the @@
mandril.
Set the thin wall removal and installation ring on 4~

top of the mandril inserted in the connecting rod. @@
Adjust the surface with the angle.
Install the cup to the mandril and secure with the

hair pin cotter.
Install the mandril to the anvil.
Adjust the rod so that the angle of the rod matches

the angle of the anvil. The rod should be horizon-
tal.
102E2447
Apply pressure to the top of the cup to push out

the bushing. Push the bushing in to the bottom of
the bore.
Remove the hair pin cotter. Remove the cup, then

slide the rod from the mandril.
1OZE2449
Remove the bushing and measure the connecting

rod bushing bore.
Caution: If the connecting rod bushing bore is not

the specified value, replace the connect-
ing rod.
Diameter
mm
42.987 MIN II
43.013 MAX
cx9brta
15-38
INSTALLATION OF PIN BORE BUSHING

Before installing the bushing, soak the bushing and
connecting rod pin end in clean 15W-40 engine oil.
Install the bushing to the mandril.
cx9bsha
Inset-t the removal/installation ring on the inside of

the stop ring.
Align the angle, set the side with the angle at the
bottom, then align the notch of the removal/instal-
lation ring with the pin’on the inside of the stop
ring, and slide it on the mandril.
cx9bshb
Install the cap and secure with the hair pin cotter.
cx9bshc
15-39
Insert the mandril and components on the cham-

fered side of the rod.
Align the angle of the bushing, connecting rod, and
stop ring.
Caution: Not all the rods have double chamfering.
In some cases, additional chamfering is
carried out to make it easier to install the
bushing, but there must be no area of the
bushing that is not supported.
Align the oil holes in the bushing and rod (use the
groove in the mandrill, and push in the mandril
and component parts until they contact the rod pin
bore. By bringing into contact in this way, the oil
hole alignment can be maintained.
hina
102E2456
Set the rod and mandril assembly on top of the

anvil. (Align so that the angle at the top of the rod
matches the angle on top of the anvil) and set so
that the rod is horizontal.
102E7.457
Use an arbor or hydraulic press to apply pressure

to the top of the cup, and push the bushing on to
the rod. Keep pushing continuously until the stop
ring is pushed in to a point where it contacts the
rod.
I 102E7.459
15-40
Check the alignment of the oil holes. It must be

possible for the rod with diameter of 3 mm to move
the rod and bushing oil hole freely.
Check the clearance between the connecting rod

bushing and connecting rod.
Using a clearance gauge (25 mm), check that the

bushing is properly fitted. The clearance gauge
(25 mm) should not enter between the bushing and
rod (B).
lViW&l;~~NG OF CONNECTING ROD
It is necessary to finish the inside diameter of the

new rod bushing. Use a Cummins rod boring ma-
chine or equivalent to machine the bushing. If a
Sannen PM-300@ or equivalent connecting rod
boring machine is adjusted properly, it can control
the tolerance for curvature and twisting, and also
the tolerance for the crankshaft - pin bore center -
center.
When carrying out the alternative repair for the B

series connecting rod, this type of boring machine
must be used.
Do not use a floating rod type honing machine.
Finishing dimensions of bushing
Inside diameter (before 19941

mm
40.053 MIN
40.067 MAX
Inside diameter (1994 only)

mm
40.019 MIN
cx9brta
40.033 MAX
15-41
Clearance of pin bushing

w
Clearance
mm
0.050 MIN
0.077 MAX
102E2461
INSPECTION OF CURVATURE AND

TWISTING OF CONNECTING ROD
0@
Calibration of test equipment
Check for curvature and twisting of the rod. To

calibrate the test equipment, use a new rod that
has had its length from center to center measured
accurately.
cxztoaa
Length from center to center

mm
191.975 MIN
192.025 MAX
102E2463
Install the connecting rod to the equipment.
Move the dial holder and set the contact of the in-
dicator on the mandril to the piston pin bore.
Tighten the bracket and secure the indicator. Set

the dial indicator to 0.
15-42
Remove the connecting rod from the equipment.
Rotate the rod 180” horizontally, then install the rod

to the equipment again.
Check again that the dial indicator is at the 0 posi-

tion.
If the dial indicator has moved even slightly from

the 0 position, set the dial to half the reading on
the scale.
This calibrates the equipment, and the connecting

rod can be installed to the equipment in any direc-
tion. The dial shows equal error on both sides of
0.
Curvature of connecting rod

mm
0.150 MAX
TESTING ALIGNMENT OF CONNECTING

ROD
Install the mandril and arborto the connecting rod,
then carry out inspection.
Install the connecting rod to the equipment.
cx2tohb
INSPECTION OF TWISTING OF CON-

NECTING ROD
Apply light pressure to the rod and rest it against
the equipment. Pass the clearance gauge over both
ends of the mandril at the opposite side of the pin.
Twisting of connecting rod

mm
0.150 MAX
cx200n b
15-43
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

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( ) Page to be deleted Discard

Pages having no marks are those previously re-

LIST OF REVISED PAGES

b 00-1 (19) 01-5-2 (12) 01-22-4 (12) 11-5-1 (12) 11-31

102 SERIES 00-2-1

00-2-2 102 SERIES

102 SERIES 00-2-3

13-269 (2) 13-322 (2) 13-375 (2) 13-428 (2) 15-18

00-2-4 102 SERIES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal